Dodge - Ram 2500 4wd - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Dodge Model Ram 2500 4wd Engine and year Truck L6-6.7L DSL Turbo VIN A (2007) 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 10 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 11 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 12 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 16 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 17 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 18 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 21 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 22 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 23 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 27 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 28 Voice Activation Module: Diagrams Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation DESCRIPTION RELAY PACK Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. Operation In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay Winch Relay: Service and Repair Relay Removal REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 35 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 36 3. Tighten the nuts to 3 Nm (25 in. lbs.). 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 Nm (85 in. lbs.). 6. Install the relay pack (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 37 Winch Relay: Service and Repair Relay Pack Removal REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). 3. Remove the nut and disconnect the red battery positive cable (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 38 NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 Nm (25 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 39 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 Nm (85 in. lbs.). 5. Install the relay pack cover (1) and install the three screws (2). 6. Install the winch assembly (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 40 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 45 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 46 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 48 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 49 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 50 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 54 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 55 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 56 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 59 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 60 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 61 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 66 Seat Heater Control Module: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 69 Seat Heater Control Module: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 74 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 75 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 76 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 77 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 78 Electronic Brake Control Module: Diagrams Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 79 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 80 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 81 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 82 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 85 Electronic Brake Control Module: Description and Operation Operation OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM 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 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 ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts . 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 88 Electronic Brake Control Module: Service and Repair Installation INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 92 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 93 Trailer Brake Control Module: Diagrams Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 94 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 99 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 100 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 101 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 102 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 103 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 108 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 112 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 116 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 126 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 127 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 128 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 129 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 134 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 135 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 136 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 137 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 143 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 144 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 145 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 146 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 151 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 152 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 153 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 154 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 157 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 158 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 159 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 160 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 161 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 162 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 163 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 164 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 165 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 166 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 167 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 168 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 169 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 170 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 171 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 172 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 173 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 174 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 175 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 176 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 177 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 178 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 179 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 180 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 181 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 182 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 183 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 184 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 187 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 188 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 189 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 190 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 191 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 192 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 193 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 194 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 195 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 196 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 197 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 198 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 199 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 200 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 201 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 202 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 203 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 204 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 205 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 206 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 207 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 208 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 209 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 210 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 211 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 212 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 213 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 214 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 217 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 220 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 221 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 222 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 227 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 228 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 229 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 232 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 233 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 234 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 267 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 268 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 269 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 270 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 271 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 272 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 273 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 279 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 284 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 285 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 286 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 287 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 293 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 298 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 299 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 300 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 301 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 306 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 307 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 308 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 309 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 310 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 311 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 312 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 322 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 327 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 328 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 329 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 330 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 340 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 341 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 342 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 343 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 344 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 345 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 346 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 353 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 354 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 355 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 356 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 357 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 358 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 359 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 360 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 361 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 362 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 363 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 364 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 365 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 366 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 367 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 368 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 369 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 370 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 371 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 372 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 373 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 374 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 375 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 376 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 377 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 378 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 379 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 380 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 381 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 382 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 383 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 384 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 385 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 386 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 390 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 391 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 392 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 393 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 394 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 395 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 397 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 398 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 399 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 400 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 401 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 402 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 403 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 404 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 405 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 406 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 407 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 408 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 412 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 413 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 414 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 416 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 420 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 427 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 430 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 433 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 436 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 438 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 439 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 444 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 445 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 446 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 449 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 450 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 451 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, 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. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 452 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 453 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 456 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 457 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 461 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 462 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 463 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 464 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 465 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 473 8w-30-17 Connector C1 pin 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 476 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 477 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 478 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 479 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 481 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 482 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 484 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 485 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 486 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 487 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 488 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 490 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 491 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 492 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 493 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 495 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Page 499 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Page 500 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Page 501 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Page 502 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal > Page 505 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 509 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 510 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 511 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 512 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 513 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 518 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 519 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 520 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 521 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 522 Component Location - 63 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 523 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 524 Air Bag Control Module: Diagrams Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 525 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 526 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 527 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 528 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 529 Component Location - 63 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 530 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is located in the passenger compartment of the vehicle, where it is secured by three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel under the center front seat or the center floor console, as the vehicle is equipped. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacles (4) has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one each from the instrument panel and the body wire harnesses. A molded plastic protective cover is installed over the ORC to provide additional moisture contamination protection to the unit. Integral latch features on each side of the cover engage a slot (5) on each side of the base of the ORC housing to secure the cover to the ORC. This protective cover must be reinstalled following any service requiring its removal. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for light and heavy-duty vehicles, and for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 533 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab vehicles, the ORC also monitors a resistor multiplexed input from the passenger airbag on/off switch. If the passenger airbag on/off switch is set to the OFF position, the ORC turns ON the passenger airbag on/off indicator and will internally disable the passenger airbag and seat belt tensioner from being deployed. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left ends of the lower radiator crossmember near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags the ORC also monitors inputs from two additional remote impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. On standard cab vehicles, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the passenger airbag on/off switch at the time of the impact. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller 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 supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the protective cover from the Occupant Restraint Controller (ORC) (1). 3. Unlatch and disconnect the two wire harness connectors (3) for the ORC from the ORC connector receptacles (2 and 4) located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three nuts (2) that secure the ORC (1) to the studs on the ORC mounting bracket (3) on the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Cover Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 536 COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. NOTE: The front seat assembly must be unfastened from the floor panel, but need not be removed from the vehicle for access to the Occupant Restraint Controller (ORC) cover for service. 2. Remove the front seat from the vehicle. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latch feature on either side of the ORC cover (1) away from the base of the ORC (2) far enough to disengage the cover from the module. 4. Remove the ORC cover from over the ORC. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 537 Air Bag Control Module: Service and Repair Installation Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller 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 supplemental restraint deployment. 1. Position the Occupant Restraint Controller (ORC) (1) over the three studs of the ORC mounting bracket (3) on the floor panel transmission tunnel, then engage the locating pin on the bottom of the right ORC mounting flange into the locating hole in the bracket. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle. 2. Install and tighten the three nuts (2) that secure the ORC to the bracket on the floor panel transmission tunnel. Tighten the nuts to 10 Nm (7 ft. lbs.). 3. Reconnect the two wire harness connectors (3) for the ORC (1) to the ORC connector receptacles (2 and 4) located on the forward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Reinstall the ORC cover onto the ORC. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 538 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Cover COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the ORC cover (1) over the Occupant Restraint Controller (ORC) (2). 2. Align the latch feature on each side of the ORC cover with the notch in each side at the base of the ORC housing. 3. Using hand pressure, press firmly and evenly downward on the ORC cover until each latch feature is fully engaged with the ORC housing. 4. Reinstall the front seat into the vehicle. 5. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams Relay - Starter Motor (Except SRT) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 548 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 549 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 550 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 551 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 552 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 553 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 554 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 555 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 556 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 557 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 558 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 559 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 560 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 561 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 562 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 563 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 564 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 565 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 566 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 567 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 568 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 569 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 570 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 571 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 572 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 583 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 584 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 589 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 590 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 591 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 592 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 598 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 599 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 604 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 605 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 606 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 607 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 608 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 609 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 610 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 611 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 612 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 613 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 614 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 615 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 616 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 617 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 620 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 621 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 622 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 623 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 624 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 625 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 626 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 631 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 632 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 633 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 634 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 635 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 636 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 637 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 638 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 639 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 640 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 641 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 642 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 643 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 644 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 645 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 646 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 647 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 648 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 649 Transmission Control System Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 656 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 657 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 658 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 659 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 660 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 663 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 664 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 665 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 666 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 671 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 675 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 680 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 686 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 687 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 688 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 691 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 694 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 695 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 696 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 700 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 701 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 702 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 703 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 704 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 707 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 712 Remote Switch: Description and Operation Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 713 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. 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 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to STEP 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to STEP 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, refer to the proper Diagnostic Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 714 Procedures to test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 717 Remote Switch: Service and Repair Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 723 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 724 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 725 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 728 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 731 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 732 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 733 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 737 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 738 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 739 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 740 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 741 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 744 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger Power Door Lock Switch: Locations Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 749 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 750 Power Door Lock Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 751 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 752 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 755 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 756 Power Door Lock Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 757 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 758 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description Power Door Lock Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description > Page 761 Power Door Lock Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch Power Door Lock Switch: Testing and Inspection Power Lock Switch POWER LOCK SWITCH The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 764 Power Door Lock Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 765 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 766 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 769 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver Power Seat Switch: Diagrams Switch-Seat-Driver Component ID: 484 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E DRIVER SEAT REAR UP DRIVER P11 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR K DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG L DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR M DRIVER SEAT FRONT UP DRIVER P19 12LG/LB N DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 777 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 GROUND Z939 14BK 3 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 4 FUSED B(+) A210 12OR/RD 5 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 6 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 7 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR 8 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 778 Power Seat Switch: Diagrams Switch-Seat-Passenger Component ID: 485 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E PASSENGER SEAT REAR UP DRIVER P12 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN K PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR L PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR M PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB N PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description Power Seat Switch: Description and Operation Description DESCRIPTION The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description > Page 781 Power Seat Switch: Description and Operation Operation OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 782 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. 3. Using an ohmmeter to test the continuity of the power seat switches in each position. If OK Refer to Power Seat Track Testing. If not OK, replace the inoperative power seat switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal Power Seat Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) 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 (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal > Page 785 Power Seat Switch: Service and Repair Installation INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver Seat Heater Switch: Locations Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 790 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 791 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 792 Seat Heater Switch: Locations Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 793 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 794 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver Seat Heater Switch: Diagrams Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 797 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 798 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 799 Seat Heater Switch: Diagrams Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 800 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 801 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 804 Seat Heater Switch: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 807 Seat Heater Switch: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 811 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 812 Sunroof / Moonroof Switch: Diagrams Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 813 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 816 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 817 Sunroof / Moonroof Switch: Testing and Inspection SWITCH - POWER SUNROOF For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 822 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 823 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 824 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 828 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 829 Lateral Accelerometer: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 830 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 831 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 834 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 838 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 839 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 840 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 843 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 844 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 847 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Steering Angle Sensor: Locations Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 851 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 852 Steering Angle Sensor: Diagrams Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 853 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 857 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 858 Traction Control Switch: Diagrams Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 859 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 860 Traction Control Switch: Description and Operation DESCRIPTION The ESP switch is located just below the heater and air conditioner controls in the center stack area of the instrument panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL 1. Remove the radio trim panel (1). 2. Disconnect the electrical connectors from the radio trim panel. 3. Remove the ESP switch (1) from the switch bank (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 863 Traction Control Switch: Service and Repair Installation INSTALLATION 1. Install the new switch (1) in the switch bank (2). 2. Reconnect the electrical connectors for the radio trim panel. 3. Install the radio trim panel (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 868 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 869 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 870 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 871 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 872 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 873 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 874 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 875 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 876 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 879 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 880 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 881 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 882 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 883 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 884 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 885 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 886 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 887 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description Wheel Speed Sensor: Description and Operation Description DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description > Page 890 Wheel Speed Sensor: Description and Operation Operation OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The 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. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 891 Wheel Speed Sensor: Testing and Inspection REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. For test procedures refer to the ABS Electrical Diagnostic. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front Wheel Speed Sensor: Service and Repair Sensor- Wheel Speed-ABS-Front Removal REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Installation INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 894 Wheel Speed Sensor: Service and Repair Sensor-Wheel Speed-ABS-Rear Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). Installation INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 895 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Installation INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 899 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 900 Yaw Rate Sensor: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 901 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 902 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 905 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 912 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 915 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left Cruise Control Switch: Diagrams Switch-Speed Control-Left Component ID: 486 Component : SWITCH-SPEED CONTROL-LEFT Connector: Name : SWITCH-SPEED CONTROL-LEFT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left > Page 921 Cruise Control Switch: Diagrams Switch-Speed Control-Right Component ID: 487 Component : SWITCH-SPEED CONTROL-RIGHT Connector: Name : SWITCH-SPEED CONTROL-RIGHT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description Cruise Control Switch: Description and Operation Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description > Page 924 Cruise Control Switch: Description and Operation Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed - The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads . The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, if equipped, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 927 Cruise Control Switch: Service and Repair Installation INSTALLATION 1. Plug electrical connector into switch, or, if equipped, connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten 15 in. lbs. ( 1.7 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 932 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 933 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 934 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 935 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 936 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 937 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 938 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 939 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 940 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 943 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 956 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 957 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 958 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 959 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 960 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 962 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 963 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 964 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 965 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 971 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 972 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 973 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 974 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 975 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 976 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 979 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 980 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 981 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 982 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 983 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 984 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 989 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 990 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 991 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 992 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 993 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 994 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 995 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 996 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 999 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1000 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1001 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1002 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1003 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1004 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1005 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1006 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1009 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1012 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1017 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1018 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1019 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 1022 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Totally Integrated Power Module (TIPM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the TIPM. Based upon the resistance in the sensor, the TIPM senses a specific voltage on the temperature sensor signal circuit. The TIPM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 1023 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (140° F), or if the sensor circuit is shorted, 60° C (130/140° F) 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, - 40° C (- 40° F) will appear in the display for Compass Mini - Trip Computer (CMTC) equipped vehicles and - -° C (- -° F) will be displayed on Electronic Vehicle Information Center (EVIC) equipped vehicles. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. TEMPERATURE SYSTEM TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the On position. The CMTC display should now read - 40° C (- 40° F) or the EVIC display should now read - -° C (- ° F). If OK, go to STEP 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the On position. The CMTC or EVIC display should now read 60° C (130/140° F). If OK, go to STEP 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. If not OK, replace the inoperative ambient temperature sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 1026 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1030 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1031 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1032 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION NOTE: Cutaway of HVAC housing shown for clarity. The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 1035 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3). 4. Remove the evaporator temperature sensor from the HVAC housing by pulling the sensor upward while tipping it forward. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 1038 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. 1. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing. 2. Connect the HVAC wire harness (1) to the evaporator temperature sensor. 3. Install the glove box. 4. Reconnect the negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1042 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1043 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1044 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1045 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1046 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1047 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1048 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1049 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1050 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1051 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1052 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1053 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1054 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1055 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1056 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1057 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1058 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 1061 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM/ECM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM also prevents the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 1064 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description > Page 1070 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 1093 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 1096 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1100 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1101 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1102 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 1105 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 1106 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 1109 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel Water In Fuel Sensor: Locations Sensor-Water In Fuel Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1114 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1115 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1116 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1117 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1118 Water In Fuel Sensor: Locations Water - In - Fuel Sensor The WIF sensor (2) is located on the bottom of the fuel filter housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1119 Water In Fuel Sensor: Diagrams Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1120 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1121 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1122 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1123 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description Water In Fuel Sensor: Description and Operation Description DESCRIPTION The Water-In-Fuel (WIF) sensor (2) is located on the bottom of the fuel filter/water separator canister (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description > Page 1126 Water In Fuel Sensor: Description and Operation Operation OPERATION 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 while the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Page 1127 Water In Fuel Sensor: Service and Repair Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1132 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1133 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1134 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1135 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1136 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1137 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1138 Backup Lamp Switch: Diagrams Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1139 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1140 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1141 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1142 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1143 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1144 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description Backup Lamp Switch: Description and Operation Description DESCRIPTION Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description > Page 1147 Backup Lamp Switch: Description and Operation Operation OPERATION The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the ON position. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 1148 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1152 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1153 Brake Light Switch: Diagrams Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1154 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 1157 Brake Light Switch: Description and Operation Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 1158 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 1161 Brake Light Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1165 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1166 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1167 Combination Switch: Diagrams Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1168 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1169 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary WASH position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, LOW speed or HIGH speed; and an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 1172 Combination Switch: Description and Operation Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. 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 automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the WASH mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1173 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1174 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1177 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1178 Combination Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1179 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description > Page 1184 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal Glove Box Lamp Switch: Service and Repair Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal > Page 1189 Glove Box Lamp Switch: Service and Repair Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1193 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1194 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1195 Headlamp Switch: Diagrams Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1196 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1197 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description Headlamp Switch: Description and Operation Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary PUSH function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. On vehicles with optional fog lamps the rotary knob also has the text PUSH and an International Control and Display Symbol icon for Front Fog Light applied to it. The cargo lamp push button is plastic with a smooth finish and the text CARGO applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description > Page 1200 Headlamp Switch: Description and Operation Operation OPERATION The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or de-energizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1201 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the cluster bezel from the instrument panel. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1202 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal Headlamp Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal > Page 1205 Headlamp Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component ID: 470 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : WHITE # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 1209 Horn Switch: Description and Operation DESCRIPTION The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1215 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1216 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1217 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1220 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1223 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1227 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1228 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1229 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1230 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1233 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 1239 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1243 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1244 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1245 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1246 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1247 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 1250 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 1253 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1257 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1258 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1259 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1260 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1261 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1262 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1263 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1264 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1265 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1266 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1267 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1268 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1269 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1272 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1275 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Description > Page 1280 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal > Page 1283 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1287 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1288 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1289 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1290 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1291 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1292 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1293 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1294 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1295 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1296 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1297 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1298 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1299 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1300 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1301 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1302 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1303 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1304 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1305 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1306 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1307 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1308 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1309 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1310 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1311 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1312 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1313 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1314 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1315 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1316 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1317 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1318 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1319 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1322 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1325 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1329 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1330 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1331 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1332 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 1335 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1340 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1341 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1342 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1343 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1344 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1345 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1346 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1347 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1350 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1351 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1352 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1353 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1354 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1355 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1356 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1357 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1360 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1363 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1368 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1369 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1370 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1371 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1372 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1373 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1376 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1377 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1378 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1379 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1380 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1381 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 1387 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1391 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1392 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1393 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1398 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1399 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1400 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1401 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1402 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1403 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1404 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1405 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1406 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1407 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1408 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1409 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1410 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1411 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1414 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1415 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1416 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1417 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1418 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1419 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1420 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1421 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1422 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1423 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1424 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1425 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1426 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1427 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1428 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1429 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 1432 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1435 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1436 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1437 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1438 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 1443 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1448 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1449 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1450 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1451 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1452 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1453 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1454 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1455 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1456 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1457 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1458 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1461 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1462 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1463 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1464 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1465 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1466 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1467 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1468 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1469 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1470 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1471 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1472 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1473 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 1476 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1479 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1480 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1481 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1512 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1513 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1514 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1515 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1516 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1517 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1518 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1524 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1525 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1526 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1536 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1537 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1538 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1543 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1544 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1545 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1546 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1547 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1548 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1549 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1559 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1560 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1561 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1571 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1572 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1573 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1574 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1575 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1576 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1577 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1580 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1581 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1582 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1583 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1584 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1585 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1586 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1587 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1588 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1589 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1590 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1591 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1592 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1593 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1594 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1595 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1596 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1597 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1598 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1599 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1600 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1601 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1602 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1603 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1604 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1605 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1606 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1607 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1608 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1609 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1612 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1613 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1614 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1615 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1616 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1617 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1618 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1619 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1620 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1621 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1622 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1623 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1624 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1625 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1626 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1627 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1628 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1629 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1630 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1631 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1632 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1633 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1634 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1635 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1636 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1637 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1638 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1639 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1640 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1641 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1642 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1645 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1646 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1649 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1650 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1651 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 1656 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1661 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1666 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1667 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1668 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1669 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1670 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1671 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1672 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1673 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1674 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1675 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 1676 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1679 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1680 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1681 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1682 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1683 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1684 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1685 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1686 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1687 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1688 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 1689 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 1692 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 1693 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 1694 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 1695 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Page 1696 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 1699 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 1700 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 1701 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 1702 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 1703 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1707 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1708 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1709 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1714 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1715 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1716 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1717 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1718 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1719 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1720 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1721 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1722 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1723 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1724 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1725 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1726 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1727 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1728 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1729 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1730 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 1731 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1737 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1738 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1739 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1740 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1741 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1742 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1743 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1744 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1747 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1748 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1749 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1750 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1751 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1752 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1753 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1754 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1757 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1760 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1764 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1765 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1766 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1767 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 1770 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 1776 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1779 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1780 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1781 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1782 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1783 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 1789 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1794 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Locations > Page 1799 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Locations > Page 1800 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Locations > Page 1801 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Description > Page 1804 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > Removal > Page 1807 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1811 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1812 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1813 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1814 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1817 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 1822 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 1823 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 1824 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1825 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1826 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1827 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1828 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 1831 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 1832 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1836 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1837 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1838 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 1843 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1844 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 1847 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 1848 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 1849 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 1853 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 1854 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 1855 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1860 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1861 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1862 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1863 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1864 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1865 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1866 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1867 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1868 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1869 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1870 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1871 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1872 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1875 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1878 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1882 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1883 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1884 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1885 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1886 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1887 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1888 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1889 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1890 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1891 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1892 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1893 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1894 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1895 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1896 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1897 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1898 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1899 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1900 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1901 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1902 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1903 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1904 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1905 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1906 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1907 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1908 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1909 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1910 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1911 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1912 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1913 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1914 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1917 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1920 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 1926 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 1931 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1936 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1937 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1938 Air Bag Deactivation Switch: Diagrams Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1939 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1940 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description Air Bag Deactivation Switch: Description and Operation Description DESCRIPTION The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this vehicle equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The OFF position nomenclature of the switch is illuminated and visible only when that switch position is selected. The ON position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if ineffective or damaged, the switch must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description > Page 1943 Air Bag Deactivation Switch: Description and Operation Operation OPERATION The passenger airbag on/off switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and the ignition switch is in the ON position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF nomenclature), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the OFF indicator will be extinguished and the passenger airbag is enabled. The OFF indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag MUX switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the OFF position, the ORC provides a ground input to the OFF indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or OFF indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. The hard wired circuits between the passenger airbag on/off switch and the ORC may be diagnosed using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the passenger airbag on/off switch or the electronic controls and communication between other modules and devices that provide some features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the passenger airbag on/off switch or the electronic controls and communication related to passenger airbag on/off switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal Air Bag Deactivation Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal > Page 1946 Air Bag Deactivation Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1951 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1952 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1953 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1954 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1955 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1956 Component Location - 64 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1957 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1960 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1961 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1962 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1963 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1964 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1965 Component Location - 64 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1966 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description Impact Sensor: Description and Operation Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Two side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description > Page 1969 Impact Sensor: Description and Operation Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through left or right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1972 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1973 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1974 Impact Sensor: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1975 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1976 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1980 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1981 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1982 Seat Belt Buckle Switch: Diagrams Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1983 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1984 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description Seat Belt Buckle Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If ineffective or damaged, the entire driver side front seat belt buckle-half unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description > Page 1987 Seat Belt Buckle Switch: Description and Operation Operation OPERATION The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description Seat Position Sensor: Description and Operation Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description > Page 1992 Seat Position Sensor: Description and Operation Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the Controller Area Network (CAN) data bus to illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal Seat Position Sensor: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal > Page 1995 Seat Position Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Seat Sensor/Switch: Locations Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1999 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2000 Seat Sensor/Switch: Diagrams Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2001 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2006 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2007 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2008 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2009 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2010 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 2013 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 2016 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 2022 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock Neutral Safety Switch: Locations Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2027 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2028 Neutral Safety Switch: Locations Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2029 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock Neutral Safety Switch: Diagrams Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2032 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2033 Neutral Safety Switch: Diagrams Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2034 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 2041 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Suspension Mode Switch: Diagrams Component ID: 461 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Description Circuit 1 LOCKER SWITCH SUPPLY T537 20YL/LG 2 LOCKER SWITCH SENSE T535 20YL/BR 3 STABILIZER BAR SWITCH SENSE T531 20YL/TN 4 SWITCH SUPPLY T536 20YL/WT 5 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY 6 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB 7 LOCKER FR/RR ILLUMINATION SENSE T534 20YL 8 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG 9 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG 10 - 11 PANEL LAMPS DRIVER E11 20OR/DB 12 GROUND Z952 20BK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2051 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2052 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2053 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 2056 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 2059 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2063 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2064 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2065 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2066 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2069 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2070 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2071 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2072 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2073 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2074 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2075 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2080 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2081 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2082 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2083 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2084 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2085 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2086 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2087 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2088 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2089 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Transmission Range > Page 2090 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2093 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2094 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2095 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2096 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2097 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2098 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2099 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2100 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2101 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2102 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Diagrams > Sensor-Transmission Range > Page 2103 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 2106 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 2107 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 2108 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > 48RE (A-618) 4 Speed > Page 2109 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Description and Operation > Page 2110 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 2113 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 2114 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 2115 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 2116 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Service and Repair > AS68RC Automatic Transmission > Page 2117 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2122 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2123 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2124 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2125 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2126 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2127 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2128 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2129 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2130 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2131 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2132 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2133 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2134 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2135 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2136 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2137 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2138 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2139 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 > Sensor-Input Speed > Page 2140 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2143 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2144 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2145 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2146 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2147 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2148 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2149 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2150 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2151 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2152 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2153 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2154 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2155 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2156 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2157 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2158 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2159 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2160 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2161 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION 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. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2164 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2165 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2168 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2169 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2170 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2171 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 2175 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 2176 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 2177 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 2187 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2192 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2193 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2194 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2195 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2196 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2197 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2198 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2201 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2202 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2203 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2204 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2205 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2206 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2207 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2212 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2213 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2214 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2215 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2216 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2217 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2218 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2219 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2220 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2223 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2224 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2225 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2226 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2227 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2228 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2229 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2230 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2231 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2234 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2235 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2236 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2237 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2238 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2239 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2240 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2241 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2242 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 2245 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2250 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2251 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2252 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2255 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2256 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2257 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 2260 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to ON, a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 2266 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes, as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than RUN, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and the A/C-heater control must be replaced if found inoperative or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite Power Window Switch: Locations Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2271 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2272 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2273 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2274 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2275 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2276 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2277 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2278 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2279 Power Window Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2280 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2281 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite Power Window Switch: Diagrams Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2284 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2285 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2286 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2287 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2288 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2289 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2290 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2291 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2292 Power Window Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2293 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2294 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description Power Window Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description > Page 2297 Power Window Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch Power Window Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2300 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2301 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2302 Power Window Switch: Testing and Inspection Window Switch WINDOW SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to STEP 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to STEP 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions . If OK, Refer to POWER WINDOWS TESTING. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL FRONT PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel 3. Remove the switch from the trim panel bezel. REAR PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 2305 Power Window Switch: Service and Repair Installation INSTALLATION FRONT PASSENGER 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) 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 Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2310 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2311 Washer Fluid Level Switch: Diagrams Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2312 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description Washer Fluid Level Switch: Description and Operation Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description > Page 2315 Washer Fluid Level Switch: Description and Operation Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal Washer Fluid Level Switch: Service and Repair Removal DIESEL ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 2318 Washer Fluid Level Switch: Service and Repair Installation DIESEL ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (5) through the rubber grommet seal and in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the left headlamp and dash wire harness (1) connector for the switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description > Page 2325 Alignment: Description and Operation Operation OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2326 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. See: Steering and Suspension/Steering/Testing and Inspection/Symptom Related Diagnostic Procedures 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2327 Suspension And Steering System Diagnosis (Part 1) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2328 Suspension And Steering System Diagnosis (Part 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment Alignment: Service and Repair Camber And Caster Adjustment CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2331 Alignment: Service and Repair Toe Adjustment TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). 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 inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2332 Alignment: Service and Repair Camber, Caster And Toe Adjustment CAMBER, CASTER AND TOE ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2333 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2334 Alignment: Service and Repair Alignment Link/Coil Suspension ALIGNMENT 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. Caster can be adjusted by rotating the cams (3) 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. 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. NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2335 Alignment: Service and Repair Curb Height Measurement (HD) CURB HEIGHT MEASUREMENT (HD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1). 2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2336 3. Rear ALL - On each side of the vehicle, measure the distance at the top of the axle tube (2) to the bottom of the frame rail (1). 4. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Front Curb Height Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2337 Rear Curb Height Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2344 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2345 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2346 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2355 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2356 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2361 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2362 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 2365 Fuel Filter: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2368 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2369 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2370 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2371 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2372 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2382 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION 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). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, 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 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 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 2386 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, 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. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Install the camshaft. Align the crankshaft and camshaft gear marks as shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2393 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2394 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2395 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. 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 ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2396 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2397 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2400 Drive Belt: Removal and Replacement Removal 5.9L/6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a 1/2 inch drive-long handle ratchet to this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate ratchet and tensioner assembly clockwise (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 5.9L/6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2401 Belt Routing - DIESEL WITH 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. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 1/2 inch ratchet to tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate ratchet and belt tensioner clockwise. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2408 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2409 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation > Page 2416 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Removal Crankcase Filter: Service and Repair Removal REMOVAL 1. Using hose clamp pliers, loosen the breather plumbing from the breather cover connections. 2. Carefully remove the breather hoses (2) from the breather cover assembly (3). 3. Remove the capscrews surrounding the parameter of the breather cover (3). 4. Separate the breather cover (3) assembly from the cylinder head cover (1). FILTER ELEMENT REMOVAL 1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the element straight up from its sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Removal > Page 2419 Crankcase Filter: Service and Repair Installation FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2424 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2425 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2426 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2427 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2428 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2429 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2434 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2435 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description > Page 2438 Fuel Filter: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2441 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2442 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2443 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2444 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2445 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 2450 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning Hose/Line HVAC: Service Precautions Warning WARNING WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately. WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is burned. An electronic leak detector is recommended. Serious or fatal injury may result from improper service procedures. WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury. WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or delicate objects from direct contact with the refrigerant. WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing property damage and serious or fatal injury. WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilo pascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service. Failure to observe this warning can result in serious burns from the heated engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning > Page 2456 Hose/Line HVAC: Service Precautions Caution CAUTION CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line Hose/Line HVAC: Description and Operation A/C Discharge Line DESCRIPTION The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C discharge line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C suction line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2459 Hose/Line HVAC: Description and Operation A/C Liquid Line DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line consists of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The A/C liquid line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. NOTE: A/C orifice tube size is different between gasoline and diesel engines. Be sure to use the correct A/C liquid line when replacement of the A/C orifice tube is required. The front section of the A/C liquid line includes the high-side service port and the rear section of the A/C liquid line includes the A/C fixed orifice tube. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the O-ring seals and gaskets, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid line is removed. The A/C liquid line cannot be repaired and must be replaced if found to be leaking or damaged, or if the fixed orifice tube is inoperative. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2460 Hose/Line HVAC: Description and Operation A/C Suction Line DESCRIPTION The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C suction line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C discharge line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed. The A/C suction line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2461 Hose/Line HVAC: Description and Operation Plumbing Description DESCRIPTION The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a A/C system consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant lines are made from lightweight aluminum and braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system. Operation OPERATION High pressures are produced in the refrigerant system when the A/C 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 refrigerant hoses at least once a year to make sure they are in good condition. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge Hose/Line HVAC: Service and Repair Line-A/C Discharge Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2464 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2465 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube 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 A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cover. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2466 Hose/Line HVAC: Service and Repair Line-A/C Liquid Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the passenger side battery. 4. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings. 5. Remove the nut (2) that secures the front section of the A/C liquid line (1) to the A/C condenser (3). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and gasket. 7. Disengage the A/C liquid line (1) from the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2467 8. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (1) to the rear section of the liquid line (3). 9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION 12. Disconnect and isolate the negative battery cable. 13. Recover the refrigerant from the refrigerant system. 14. Remove the passenger side battery. 15. Disengage the rear section of the A/C liquid line (2) from the body retaining clip (5). 16. Remove the secondary retaining clip (1) from the spring-lock coupler that secures the front section of the A/C liquid line (6) to the rear section of the A/C liquid line. 17. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 18. Remove the secondary retaining clip (3) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator tube (4). 19. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line from the evaporator tube and remove and discard the O-ring seals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2468 20. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator tube, 21. Remove the rear section of the A/C liquid line from the engine compartment. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Position the front section of the A/C liquid line (1) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (3). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2469 6. Engage the A/C liquid line (1) into the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. 7. Lubricate a new O-ring with clean refrigerant oil and install it and a new gasket onto the front liquid line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the condenser port. 9. Install the nut (1) that secures the A/C liquid line to the A/C condenser (3). Tighten the nut to 23 Nm (17 ft. lbs.). 10. Position the air seal over the right end of the A/C condenser and install the air seal retainers. 11. Install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Adjust the refrigerant oil level. 15. Charge the refrigerant system. REAR SECTION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2470 16. Position the rear section of the A/C liquid line (2) into the engine compartment. 17. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator tube (4). 18. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Connect the rear section of the A/C liquid line to the evaporator tube. 20. Install the secondary retaining clip (3) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator tube. 21. Engage the A/C liquid line into the body retaining clip (5). 22. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 23. Connect the rear section of the A/C liquid line (6) to the front section of the liquid line. 24. Install the secondary retaining clip (1) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 25. Install the passenger side battery tray. 26. Reconnect the negative battery cables. 27. Evacuate the refrigerant system. 28. Adjust the refrigerant oil level. 29. Charge the refrigerant system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2471 Hose/Line HVAC: Service and Repair Line-A/C Suction Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2472 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C suction and discharge line assembly to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2473 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube 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 A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cove. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. Power Steering Line/Hose: Service and Repair Hoses - I.F.S. Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2478 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2479 Power Steering Line/Hose: Service and Repair Hoses - Link/Coil Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2480 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2486 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2487 Brake Fluid: Specifications BRAKE FLUID Mopar DOT 3 and SAE J1703 or equivalent. NOTE: If DOT 3 is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2488 Brake Fluid: Description and Operation BRAKE FLUID 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2489 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2490 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2495 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Page 2496 Clutch Fluid: Specifications Chrysler does not provide a fluid type specification for the master/slave cylinder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2501 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................ 22.6 qts (21.4L) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2504 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description Coolant COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year 100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. 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% 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. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of 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 or freeze-up on a cooling system designed for ethylene-glycol. Propylene- glycol also has poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene-glycol. HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 2507 Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. 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 specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37 °C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 2508 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 2509 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2514 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2519 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2524 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2529 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2534 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2535 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2536 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2537 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION Service Fill - 42RLE ............................................................................................................................. ....................................................... 3.8L (4.0 Quarts) Overhaul Fill - 42RLE ...................................... ........................................................................................................................................... 8.3L (8.7 Quarts) Service Fill - 45RFE/545RFE 4X2 .............................................................................................................................................................. 5.2L (5.5 Quarts) 4X4 .......................................................................................................................... .................................................................................... 6.2L (6.5 Quarts) Overhaul - 45RFE/545RFE ....................................................................................................................................................... 14 -16L (14.8-16.9 Quarts) Service Fill - 48RE ............................................................................................................................... ....................................................... 3.8L (4.0 Quarts) Overhaul - 48RE .............................................. ..................................................................................................................... 14 - 16L (14.8 - 16.9 Quarts) Service Fill - 68RFE 4X2 ..................................................................................................................... ....................................................... 5.2L (5.5 Quarts) 4X4 .................................................................. ............................................................................................................................................ 6.2L (6.5 Quarts) Overhaul - 68RFE ................................................................................................................... ............................................ 15.6 - 16.6L (16.4 - 17.5 Quarts) Service Fill - AS68RC .......................................................................................................................... ....................................................... 6.8L (7.2 Quarts) Overhaul - AS68RC ......................................... ......................................................................................................................................... 13L (13.74 Quarts) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2540 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2543 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2544 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2547 transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2548 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2549 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid, refer to FLUID - STANDARD PROCEDURE and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2550 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2551 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2552 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2553 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2554 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2555 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2556 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2557 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2558 Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2563 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2568 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications G56 ...................................................................................................................................................... .......................................................... 5.6 L (12 pints) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2571 Fluid - M/T: Fluid Type Specifications Mopar ATF +4 Transmission Fluid Note: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2576 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle C205FD .............................................................................................................................. ....................................................................... 1.6 L ( 56 ounces) 9 1/4 AA ......................................... ............................................................................................................................................................ 2.2 L (74 ounces) 9 1/4 AA EL ............................................................................................................ ................................................................................... 2.0 L (68 ounces) Rear Axle 9 1/4 .................................................................................................................................... ....................................................................... 2.1 L (72 ounces) 10 1/2 AA ........................................ ........................................................................................................................................................... 2.5 L (85 ounces) 10 1/2 AA EL .......................................................................................................... ................................................................................... 2.5 L (85 ounces) 11 1/2 AA Open .................. .............................................................................................................................................................. ....... 4.2 L (142 ounces) 11 1/2 AA Trac-Rite ...................................................................................... .......................................................................................... 4.0 L (135 ounces) Note: With Track-Lok add 118 ml (4 oz) of Limited Slip Additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2579 Fluid - Differential: Fluid Type Specifications Note: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. Front Axle c205FD - Mopar Gear Lubricant 75W-90 9 1/4 AA - Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL - Mopar Synthetic Gear Lubricant 75W-90 Rear Axle 9 1/4 - Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA - Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL - Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA - Mopar Synthetic Gear Lubricant 75W-90 Note: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differential DO NOT require Limited Slip Additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2584 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV241 GEN II ...................................................................................................................................... ....................................................... 1.6 L 3.4 (pints) NV243 ................................................................ .......................................................................................................................................... 1.6 L (3.4 Pints) NV244 GEN II ............................................................................................................................ ................................................................. 1.6 L (3.4 pints) NV246 ...................................................... .................................................................................................................................................. 1.9 9L (4.0 pints) NV271 ................................................................................................................................. ....................................................................... 1.89 L (4.0 pints) NV273 .............................................. .......................................................................................................................................................... 1.89 L (4.0 pints) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2587 Fluid - Transfer Case: Fluid Type Specifications All Except NV246 Recommended lubricant for the NV241 GEN II, NV271, NV243, NV 244 GEN II, and NV273 transfer cases is Mopar ATF +4 Automatic Transmission Fluid. NV246 Recommended lubricant for the NV246 transfer case is Mopar NVG 246 Automatic Transmission Fluid or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2590 Fluid - Transfer Case: Service and Repair NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2591 Fluid - Transfer Case: Service and Repair NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2592 Fluid - Transfer Case: Service and Repair NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2593 Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2594 NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2595 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2596 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2601 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ................................................. 11.4Liters (12.0 Qt) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2604 Engine Oil: Fluid Type Specifications ENGINE OIL - DIESEL ENGINES Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ-4/SM (5.9L), or CJ-4 (6.7L), or higher that meets Cummins CES 20081 Standards. Low ash diesel engine oil is REQUIRED for the 6.7L engine, use MOPAR® MaxPro 15W-40 6700 Diesel DPF diesel engine oil, or equivalent. SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 15W-40 engine oils that meet Chrysler material standard MS-10902, be used in accordance to ACEA B3, B4 specification. European Grade 15W-40 oils that meet Association des Constructeurs Europe■ens d' Automobiles (European Automobile Manufacturers Association) (ACEA) specifications, are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15°C (5°F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2605 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2606 Engine Oil: Service and Repair ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. NOTE: Change engine oil and filter at intervals specified in the owner's manual. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter. 5. Install new oil filter. 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. 9. Fill the engine with the correct grade of new oil. 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2611 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2612 Power Steering Fluid: Specifications POWER STEERING FLUID Mopar ATF +4 Automatic Transmission Fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2613 Power Steering Fluid: Description and Operation DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2614 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4. Do not overfill the power steering system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2615 Power Steering Fluid: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a the vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications Refrigerant: Specifications R-134a Refrigerent Charge Capacity 1. 3.7/4.7/5.7 L ..................................................................................................................................... .......................................... 0.728 kg (1.604 lbs.) 2. 5.9/6.7 L .............................................................. ....................................................................................................................... 0.850 kg (1.873 lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a Chlorofluorocarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description > Page 2621 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Page 2622 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and serious or fatal injury . Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2625 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2626 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 to the refrigerant system. 3. Refer to A/C SPECIFICATIONS or the Underhood HVAC Specification Label for the proper amount of the refrigerant charge. 4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 5. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 6. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 7. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle ( about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch circuits and repair as required. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in serious or fatal injury. 8. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. 9. Disconnect the charging station from the refrigerant system service ports. 10. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2627 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE- The center manifold hose (Yellow, or White, with Black stripe) (3) is used to Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2628 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. HIGH PRESSURE GAUGE HOSE- The high pressure hose (Red with Black stripe) (4) attaches to the high side service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is installed on the high side service port. A/C high-side pressures can be read using a scan tool. LOW PRESSURE GAUGE HOSE- The low pressure hose (Blue with Black stripe) (5) attaches to the low side service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L or 5.7L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L or 6.7L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description > Page 2634 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 2635 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. 3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the new A/C compressor onto the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2640 Brake Bleeding: Service and Repair Pressure Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2641 Brake Bleeding: Service and Repair Master Cylinder MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2642 Brake Bleeding: Service and Repair ABS Brake Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of a scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2643 Brake Bleeding: Service and Repair Booster-Hydro-Boost Brake BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 2648 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 2649 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) Fuse: Locations Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2655 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2656 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2657 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2658 Fuse: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse: Application and ID Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2681 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2682 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2683 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2684 Fuse: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description Fuse: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the new vehicle preparation procedures and then disconnect it again until new vehicle delivery to the customer. A laser printed fuse layout map is integral to the TIPM cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the TIPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description > Page 2687 Fuse: Description and Operation Operation OPERATION The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) Fuse Block: Locations Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2692 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2693 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2694 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2695 Fuse Block: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse Block: Application and ID Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2718 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2719 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2720 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2721 Fuse Block: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2726 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2727 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2728 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2731 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2732 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2733 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 2739 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures Maintenance Required Lamp/Indicator: Procedures This vehicle is not equipped with a Maintenance Required Lamp/Indicator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 2744 Maintenance Required Lamp/Indicator: Reset Procedure PERFORM SERVICE INDICATOR - RESET The "Perform Service" message will display on the Electronic Vehicle Information Center each time you turn the ignition switch to the ON/RUN position to indicate a emission maintenance is required. To reset the "Perform Service" indicator system (after performing the scheduled maintenance) refer to the following procedure: - 1. Turn the ignition switch to the ON position (Do not start engine). - 2. Press and release the brake pedal two times. - 3. Fully depress the accelerator pedal slowly two times within 10 seconds. - 4. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illumination when you start the vehicle, the "Perform Service" indicator did not reset. If necessary repeat this procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 2749 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair OIL CHANGE INDICATOR - RESET To reset the "Oil Change Required" indicator (after performing the scheduled maintenance) refer to the following procedure: 1. Turn the ignition switch to the ON position (Do not start engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the "Oil Change Required" indicator message illuminates when you start the vehicle, the indicator did not reset. If necessary repeat this procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 2759 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications TIRE REVOLUTIONS PER MILE TIRE REVOLUTIONS PER MILE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire Tires: Description and Operation Tire TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 2765 Tires: Description and Operation Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 2766 Tires: Description and Operation Radial - Ply Tires RADIAL - PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KMH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 2767 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 2768 Tires: Description and Operation Full Size, Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire, It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges Tires: Testing and Inspection Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2771 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2772 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2773 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2774 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRES Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2777 Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the vehicles Owners Manual. Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEEDS For proper tire pressure specification refer to the Owners Manual. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2778 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 2783 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels Wheels: Description and Operation Description - Wheels WHEELS Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, the rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels > Page 2786 Wheels: Description and Operation Description - Wheel Design WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2787 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 2792 9. Remove the support and lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 2793 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 2794 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. NOTE: Failure to use a back and forth motion could damage the wheel skin chrome finish. 4. The wheel skins can now be removed from the wheel. Use the flat end of the lug nut wrench to pry off the wheel skins. Make sure that the flat end is inserted and use a back and forth motion to remove the wheel skin. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 2799 Wheel Cover: Service and Repair Installation Front FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistant gap between the skin/ cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Rear REAR 1. Install one 1 1/2 in. valve stem extension on each rear inner wheel. NOTE: A 3/8 in. drive 10mm deep wheel socket with a 10 in. or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 in. valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike thew wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE Torque Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal Wheel Fastener: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal > Page 2809 Wheel Fastener: Service and Repair Installation INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2815 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures INSPECTION Camshaft Camshaft Dimensions 1. Inspect the valve lobes (1) and bearing journals (2) for cracks, pitting, scoring, or generally excessive wear. Replace any camshaft that exceeds the allowable limits. 2. Measure the bearing journals and lobes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2821 CAUTION: If Camshaft lobes are worn, requiring camshaft replacement, it is necessary to replace the tappets also. Camshaft Bushing/Bores Camshaft bores No. 2-6 do not use a bushing. 1. Inspect the camshaft bushing and bores for signs of excessive wear. 2. Measure the camshaft bushing and bores with a telescoping bore gauge and micrometer. 3. Inspect the camshaft bushing (1) oil holes for alignment with cylinder block. Camshaft Gear Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary, camshaft and gear are replaced as an assembly. Thrust Plate Camshaft Thrust Plate Thickness Chart Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these specifications: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2822 Camshaft: Removal and Replacement Camshaft - Removal CAMSHAFT 1. Disconnect both battery negative cables. 2. Recover A/C refrigerant (if A/C equipped). 3. Raise vehicle on hoist. 4. Drain engine coolant into container suitable for re-use. 5. Lower vehicle. 6. Remove radiator upper hose. 7. Remove viscous fan/drive/shroud assembly. 8. Disconnect the coolant recovery bottle hose from the radiator filler neck. 9. Disconnect lower radiator hose from radiator outlet. 10. Automatic Transmission models: Disconnect transmission oil cooler lines from front of radiator using Special Tool 6931 (unless equipped with finger-release disconnect). 11. Remove radiator mounting screws and lift radiator out of engine compartment. 12. Remove upper radiator support panel. 13. If A/C equipped, disconnect A/C condenser refrigerant lines. 14. Disconnect charge air cooler piping from the cooler inlet and outlet. 15. Remove the two charge air cooler mounting bolts. 16. Remove charge air cooler (and A/C condenser if equipped) from vehicle. 17. Remove accessory drive belt. 18. Remove accessory drive belt tensioner. 19. Remove the fan support/hub assembly. 20. Remove crankshaft damper. 21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the sealing surfaces. Remove dust seal with cover. 22. Using Special Tool 7471-B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the crankshaft and the camshaft gears. 23. Remove the cylinder head cover. 24. Remove the rocker arms, cross heads, and push rods. Mark each component so they can be installed in their original positions. NOTE: The #5 cylinder intake and the #6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2823 25. Raise the tappets as follows, using the wooden dowel rods provided with the Miller Tool Kit 8502. a. Insert the slotted end of the dowel rod into the tappet. The dowel rods for the rear two cylinders will have to be cut for cowl panel clearance. Press firmly to ensure that it is seated in the tappet. b. Raise the dowel rod to bring the tappet to the top of its travel, and wrap a rubber band around the dowel rods to prevent the tappets from dropping into the crankcase. c. Repeat this procedure for the remaining cylinders. 26. Verify that the camshaft timing marks are aligned with the crankshaft mark. 27. Remove the bolts from the thrust plate. 28. Remove engine mount through bolts. 29. Install engine support fixture special tool #8534, and steel bracket/wing nut special tool #8534A. 30. Raise engine enough to allow camshaft removal. 31. Remove the camshaft, gear and thrust plate. Camshaft - Installation CAMSHAFT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2824 1. Lubricate the camshaft bushing and bores with fresh engine oil or suitable equivalent. 2. Liberally coat the camshaft lobes, journals, and thrust washer with fresh engine oil or suitable equivalent. CAUTION: When installing the camshaft, DO NOT push it in farther than it will go with the thrust washer in place. 3. Install the camshaft and thrust plate. Align the timing marks as shown. 4. Install the thrust plate bolts and tighten to 24 Nm (18 ft. lbs.) torque. 5. Measure camshaft back lash and end clearance. 6. Remove the wooden dowel rods and rubber bands from the tappets. 7. Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the tappets. 8. Lubricate the valve tips with engine oil and install the crossheads in their original locations. 9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 10. Verify valve lash adjustment. 11. Install the cylinder head cover. 12. Install gear housing cover. Install front crankshaft dust seal. 13. Install the crankshaft damper. 14. Install the fan support/hub assembly. 15. Install the power steering pump. 16. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.). 17. Install the accessory drive belt. 18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten the mounting bolts to 2 Nm (17 in. lbs.) torque. 19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nm (95 in. lbs.) torque. 20. Install the radiator upper support panel. 21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11 Nm (95 in. lbs.) torque. 22. Raise vehicle on hoist. 23. Connect radiator lower hose and install clamp. 24. Connect transmission auxiliary oil cooler lines (if equipped). 25. Lower vehicle. 26. Install the fandrive/shroud assembly. 27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud. 28. Connect the coolant recovery hose to the radiator filler neck. 29. Add engine coolant. 30. Charge A/C system with refrigerant (if A/C equipped). 31. Connect the battery negative cables. 32. Start engine and check for engine oil and coolant leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2825 Camshaft Bearings - Removal CAMSHAFT BEARINGS NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machining and installation of service bushings. If badly worn, replace the cylinder block. 1. Remove the camshaft. 2. Remove the bushing from the No.1 bore. 3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing. Camshaft Bearings - Installation CAMSHAFT BEARINGS 1. Apply a coating of Loctite(R) 640 Adhesive to the backside of the new bushing. Avoid getting adhesive in the oil hole. 2. Use a universal cam bushing installation tool and install the front bushing (1) so that it is even with the front face of the cylinder block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole. 3. Measure the installed bushings at the front bore. The minimum inside diameter is 54.083 mm (2.1293 inch), and the maximum inside diameter is is 54.147 mm. (2.1318 in.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures Cleaning CLEANING Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or compressed air. Inspection INSPECTION 1. Visually inspect the tappet the tappet socket, stem, and face for excessive wear, cracks, or obvious damage. 2. Measure the tappet stem diameter. Replace the tappet if it falls below the minimum size. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2830 Lifter / Lash Adjuster: Removal and Replacement Removal REMOVAL NOTE: This procedure requires use of Miller Tool 8502 Tappet Replacement Kit. 1. Remove camshaft. 2. Insert the trough (1) (provided with tool kit) the full length of the camshaft bore. Make sure the cap end goes in first and the open side faces up (towards tappets). 3. Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair. 4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough. 5. Carefully remove trough (do not rotate) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2831 6. Re-install trough (1) and repeat procedure on remaining tappets. Installation INSTALLATION 1. Insert the trough (1) the full length of the camshaft bore. Again, make sure the cap end goes in first and the open side faces up (towards tappets). 2. Lower the tappet installation tool through the push rod hole and into the trough. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2832 3. Retrieve the tappet installation tool using the hooked rod provided with the tool kit. 4. Lubricate the tappet with clean engine oil or suitable equivalent and install the tappet to the installation tool. 5. Pull the tappet up and into position. If difficulty is experienced getting the tappet to make the turn into the tappet bore, wiggle the trough while gently pulling up on the tappet. 6. With the tappet in place, rotate the trough one half turn so the open side is down (toward crankshaft). 7. Remove the tappet installation tool from the tappet. 8. Re-install a dowel rod and secure the rod with a rubber band. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2833 9. Rotate the trough one half turn and repeat the procedure for the remaining tappets. 10. Install the camshaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2839 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2840 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover. 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2841 NOTE: The #5 cylinder intake and exhaust, and #6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment. 5. Install cylinder head cover. 6. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rods Connecting Rods Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2846 Connecting Rod Bearing: Service and Repair CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE 1. Measure the connecting rod bore with bearings removed and the bolts tightened to 100 Nm (73 ft. lbs.) torque.. 2. Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 Nm (73 ft. lbs.) torque. Measure within 20° arc from each side of the parting line. Also measure 90° from parting line. Record the smallest and largest diameter. Measure the diameter of the rod journal at the location shown. Calculate the average diameter for each side of the journal. Determine minimum bearing clearance by calculating the differance between the smallest connecting rod bore diameter with the bearing installed and the average diameter for each side of the crankshaft journal. Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore diameter and the average diameter with the bearing installed for each side of the crankshaft journal. If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the crankshaft to the next smaller size and use oversize rod bearings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rods Connecting Rods Connecting Rod-Bolts Step 1 .................................................................................................................................................. ................................................. 30 Nm (22 ft. lbs.) Step 2 ................................................................... ................................................................................................................................ 60 Nm (44 ft. lbs.) Step 3 .................................................................................................................................................. .................................................. Rotate 60 degrees Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2850 Connecting Rod: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank. PISTON Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air. CONNECTING ROD Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air. Piston and Connecting Rod - Inspection CONNECTING ROD Inspect the connecting rod for damage and wear. The I-Beam section of the connecting rod cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage. Measure the connecting rod pin bore (1). The maximum diameter is 40.042 mm (1.5765 inch), minimum diameter is 40.019 mm (1.5756 inch). If out of limits, replace the connecting rod. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2853 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head. 3. Remove the oil pan and suction tube. 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston. 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2854 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan. 17. Install the cylinder head onto the engine. 18. Install a new filter and fill the crankcase with new engine oil. Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Cap-Bolts (Previously Used) Step 1 .................................................................................................................................................. .................................................. 60 Nm (44 ft. lbs.) Step 2 .................................................................. .................................................................................................................................. 80 Nm (59 ft. lbs.) Step 3 .......................................................................................................................................... ...................................................................... Rotate 90° Crankshaft Main Cap-Bolts (New Main Bearing Capscrews) Step 1 .................................................................................................................................................. ............................................... 120 Nm (89 ft. lbs.) Step 2 ................................................................... .............................................................................................................................. Loosen Completely Step 3 .................................................................................................................................................. ................................................. 60 Nm (44 ft. lbs.) Step 4 ................................................................... ................................................................................................................................. 85 Nm (63 ft. lbs.) Step 5 .......................................................................................................................................... ......................................................... Rotate 120 degrees Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2858 Crankshaft Main Bearing: Service and Repair MAIN BEARING CLEARANCE Main Bearing Bore Diameter Chart Inspect the main bearing bores for damage or abnormal wear. 1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 Nm (130 ft. lbs.). 2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to 176 Nm (130 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2859 Crankshaft Main Journal Diameter Chart 3. Measure the diameter of the main journal at the locations shown. Calculate the average diameter for each side of the journal. 4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the crankshaft journal is within limits, replace the main bearings. If not within specifications, grind the crankshaft to next size and use oversize bearings. 5. Measure thrust distance at the No.6 position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Remove the oil pan drain plug and drain the engine oil. Re-install plug and torque to 50 Nm (44 ft. lbs.) torque. 4. Remove transmission and transfer case (if equipped) from vehicle. 5. Remove flywheel or torque converter drive plate. 6. Remove flywheel adapter plate. 7. Disconnect starter cables from starter motor. 8. Remove starter motor and transmission adapter plate assembly. 9. Remove four 4 oil pan rear bolts. Slide a feeler gauge between the seal retainer and oil pan gasket to break the seal. 10. Remove the six 6 retainer-to-block bolts (3). 11. Remove the rear seal retainer, and gasket (2). 12. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 2864 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Installation INSTALLATION 1. If using the old seal retainer, the crankshaft seal must be replaced. 2. Inspect oil pan gasket for nicks or cuts. If gasket is damaged, the oil pan must be removed and gasket must be replaced. Wipe oil pan gasket dry and apply light coating of RTV. 3. Using the retainer alignment/seal installation tool provided in the seal service kit, install the alignment tool into the retainer and install to the cylinder block, using a new gasket. Tighten the six (6) mounting bolts by hand. 4. The seal alignment tool is used to align rear cover properly. Starting with the center two bolts, tighten the retainer in a circular pattern to 10 Nm (89 in. lbs.). Remove the alignment tool. CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 5. Make sure the provided seal pilot (1) is installed into the new crankshaft seal (3). Use the alignment/installation tool and press the seal onto the crankshaft. Alternately drive the seal at the 12, 3, 6 and 9 o'clock positions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 2865 6. Remove the alignment tool and trim the retainer gasket (1) even with the oil pan mounting surface. 7. Remove the seal pilot. 8. Apply a small amount of Mopar(R) Silicone Rubber Adhesive Sealant to the oil pan rail T-joints. 9. Install the four (4) oil pan rear mounting bolts and torque to 28 Nm (21 ft. lbs.). 10. Install new rectangular ring seal for cam bore. 11. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). 12. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the dual mass flywheel with crankshaft adapter. Tighten bolts to 137 Nm (101 ft. lbs.). 14. Install the starter motor. 15. Install the transmission and transfer case (if equipped). 16. Lower vehicle. 17. Fill the crankcase with new engine oil. 18. Connect the battery negative cables. 19. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Description and Operation Crankshaft: Description and Operation DESCRIPTION The crankshaft is a forged steel, internally balanced unit. It is supported by seven main bearings, with position number six designated as the thrust journal. The crankshaft is held in place by main caps and 12 mm capscrews. The crankshaft also has internal cross drillings to supply the connecting rods with engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Gear - Removal Crankshaft: Service and Repair Crankshaft Gear - Removal REMOVAL - GEAR 1. Remove the gear housing cover. 2. Split the gear and remove it from the crankshaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Gear - Removal > Page 2871 Crankshaft: Service and Repair Crankshaft Gear - Installation INSTALLATION - GEAR 1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth. 2. If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it protruding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft. WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes. 3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur. 4. Apply a thin coat of lubricant to the nose of the crankshaft. 5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description DESCRIPTION WARNING: Do not operate engine unless block heater cord has been disconnected from power source and secured in place. The power cord must be secured in its retaining clips and routed away from exhaust manifolds and moving parts. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L / 4.7L gas powered engines have the block heater located to the rear on the right side of the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 2876 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 2877 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 2878 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal 5.9L/6.7L DIESEL 1. Disconnect the battery negative cables. 2. Drain coolant from radiator and cylinder block. 3. Unscrew the power cord retaining cap and disconnect cord from heater element. 4. Using a suitable size socket, loosen and remove the block heater element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 2881 Engine Block Heater: Service and Repair Engine Block Heater - Installation 5.9L/6.7L DIESEL 1. Clean and inspect the threads in the cylinder block and heater element. 2. Coat heater element threads with Mopar(R) Thread Sealer with Teflon. 3. Screw block heater (1) into cylinder block and tighten to 75 Nm (55 ft. lbs.). 4. Connect block heater cord and tighten retaining cap. 5. Fill cooling system with recommended coolant. 6. Start and warm the engine. 7. Check block heater for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft damper Torque bolts to ...................................................................................................................... 40 Nm (30 ft. lbs.) plus an additional 60° Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures Harmonic Balancer - Crankshaft Pulley: Procedures INSPECTION NOTE: The Crankshaft damper is of viscous design and the speed indicator is incorporated into the crankshaft damper. 1. Inspect the damper hub for cracks and replace if any are found. 2. If the crankshaft damper is leaking fluid, discard and replace the crankshaft damper. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures > Page 2887 Harmonic Balancer - Crankshaft Pulley: Removal and Replacement Vibration Damper - Removal REMOVAL 1. Remove the accessory drive belt. 2. Remove the four (4) damper to crankshaft bolts and remove damper. Vibration Damper - Installation INSTALLATION 1. Install the crankshaft damper and bolts. Tighten bolts to 40 Nm (30 ft. lbs.) torque, plus an additional 60°. NOTE: The damper must be installed so the hole is located over the dowel pin. 2. Install the accessory drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons Pistons Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2891 Piston: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank. PISTON Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air. CONNECTING ROD Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air. Piston and Connecting Rod - Inspection PISTONS Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Measure the piston skirt diameter. If the piston is out of limits, replace the piston. The upper groove only needs to be inspected for damage. Use a new piston ring (2) to measure the clearance in the intermediate ring groove. Minimum clearance is 0.045 mm (0.0018 inch), maximum clearance is 0.095 mm (.0037 inch). If the clearance of the intermediate ring exceeds specifications, replace the piston (3). Use a new oil ring to measure the clearance in the oil groove. Minimum clearance is 0.040 mm (0.0016 inch), maximum clearance is 0.085 mm (.0033 inch). If the clearance exceeds specifications, replace the piston. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2894 Measure the pin bore (2). The maximum diameter is 40.012 mm (1.5753 inch), Minimum is 40.006 mm (1.575 inch). If the bore is over limits, replace the piston (1). Inspect the piston pin for nicks, gouges and excessive wear. Measure the pin diameter (1). The minimum diameter is 39.990 mm (1.5744 inch), maximum 40.003 mm (1.5749 inch). If the diameter is out of limits, replace the pin (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2895 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head. 3. Remove the oil pan and suction tube. 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston. 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2896 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan. 17. Install the cylinder head onto the engine. 18. Install a new filter and fill the crankcase with new engine oil.Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pins Piston Pins Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Piston Rings Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2903 Piston Ring: Service and Repair PISTON RING FITTING 1. Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identified as shown. 2. Position each ring in the cylinder and use a piston (1) to square it with the bore at a depth (3) of 89.0 mm (3.5 inch). Piston Ring Gap Chart 3. Use a feeler gauge to measure the piston ring gap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2904 4. The top surface of all of the compression rings are identified with the word TOP or the supplier's MARK. Assemble the rings with the word TOP or the supplier's MARK up. 5. Position the oil ring expander (2) in the oil control ring (1) groove (bottom groove). NOTE: There is no (TOP) mark on the oil ring. 6. Install the oil control ring (1) with the end gap OPPOSITE the ends on the expander. 7. Install the intermediate piston ring in the second groove. 8. Install the top piston ring in the top groove. 9. Position the rings as shown. - Install top and second compression rings on piston with ring gaps 180° apart. - Install oil control ring with ring gap 90° from top and second ring. Do not position gaps over wrist pin hole. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION 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). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, 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 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 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > Page 2909 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, 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. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2915 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2916 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover. 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2917 NOTE: The #5 cylinder intake and exhaust, and #6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment. 5. Install cylinder head cover. 6. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures Valve Cover: Procedures Cleaning CLEANING Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use. Inspection INSPECTION The cylinder head cover gasket and rocker housing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone construction, the defective components should be replaced. Also replace gasket if it is no longer flexible. Inspect cylinder head cover rubber isolated capscrews for cracks, nicks, or tears.Do not reuse gasket if it has been removed from the groove in the rocker housing or cylinder head cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 2922 Valve Cover: Removal and Replacement Rocker Housing ROCKER HOUSING 1. Remove the breather cover and the cylinder head cover. 2. Remove injector harness nuts from injectors. 3. Remove cylinder head cover gasket. 4. Remove rocker housing bolts. 5. Remove rocker housing and gasket. Cylinder Head Cover CYLINDER HEAD COVER 1. Disconnect both negative battery cables. 2. Remove the Breather Cover Capscrews (8-M6 screws). 3. Remove the CCV breather and filter cover (3). 4. Disconnect CCV Tube (4) at the CDR valve (one spring clamp) and remove 10mm nut from tube bracket at EGR Cooler support bracket stud. 5. Disconnect CDR valve Tube to Air Inlet Silencer (Spring Clamp). 6. Disconnect CDR/Valve cover pressure sensor connector. 7. Remove Oil fill cap. 8. Remove CCV oil drains (2) from valve cover (2 hoses). 9. Disconnect both injector harness connectors (1). 10. Remove six (6) valve cover capscrews (10mm). 11. Remove the valve cover. 12. Loosen injector wire nuts from the valve cover gasket (8mm). 13. Remove gasket. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 2923 1. Remove cylinder head cover. 2. Disconnect injector harness connectors (3) at cylinder head cover gasket. 3. Remove injector solenoid nuts (1) at injectors. 4. Remove cylinder head cover gasket (2). Rocker Housing ROCKER HOUSING 1. Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove. 2. Inspect rocker housing gasket for proper installation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak. CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, The gasket could fall out or be damaged. 3. Install the rocker housing. Carefully guide the rocker housing evenly down onto the cylinder head. 4. Install rocker housing bolts and tighten finger tight. 5. Torque bolts, working from center out, to 24 Nm (18 ft. lbs.). Cylinder Head Cover CYLINDER HEAD COVER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 2924 NOTE: Gasket must be completely dry and free of oil before installation. 1. Wipe oil from the valve cover gasket, rocker box, and valve cover. 2. Inspect valve cover gasket for tears, or splits. Replace if necessary. 3. Install the valve cover gasket on the rocker box. 4. Install the injector nuts (8 mm) to injector studs. Torque to 1.25 Nm (11 in. lbs.). 5. Install valve cover and valve cover capscrews (10mm). tighten from center out. Torque to 24 Nm (18 ft. lbs.). 6. Install the valve cover CCV drain hoses (2). 7. Remove any oil from the CCV seal area and install the CCV filter. 8. Install the CCV cover and capscrews (6mm). Torque to 10 Nm (89 in. lbs.). 9. Connect CDR valve tube to Air Inlet Silencer (spring clamps). 10. Connect the Breather/Valve Cover Pressure sensor. 11. Install oil fill cap. 12. Connect the batteries. 13. Start the vehicle and check for leaks. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 2925 1. Clean oil from cylinder head cover gasket 2. Inspect cylinder head cover gasket for cuts or damage. Replace if damaged. 3. Place cylinder head cover gasket on top of rocker housing (2). 4. Install injector solenoid nuts (1) at injectors. Torque to 1.25 Nm (11 in. lbs.). 5. Connect injector harness connectors (3) at cylinder head cover gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair VALVES, GUIDES AND SPRINGS REMOVAL 1. Remove cylinder head. 2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench. 3. Install the valve spring compressor mounting base (1) as shown. 4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks. 5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2929 6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations. 7. Repeat the procedure on all cylinders to be serviced. CLEANING Clean the valve stems with crocus cloth or a Scotch-Brite(TM) pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air. INSPECTION Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent. Measure the valve stem diameter in three places as shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2930 Valve Guide Bore Specifications Measure the cylinder head valve guide bore. Measure valve margin (rim thickness). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2931 Measure the valve spring free length and maximum inclination. Test valve spring force with tool C-647 (1). Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.). INSTALLATION 1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves. 2. Install the valves in their original position. The exhaust valves are identified by a dimple on the valve head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2932 3. Install the valve (2), springs (4), and retainer (5). 4. Install the valve spring compressor tool 8319-A (1) as shown. 5. Compress the valve springs and install the valve retaining locks. 6. Remove the compressor and repeat the procedure on the remaining cylinders. 7. Install new o-ring and sealing washer on injector. 8. Lubricate o-ring and injector bore. 9. Verify sealing washer (shim) was removed with old injector. 10. Install injector. 11. Install the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation Valve: Description and Operation DESCRIPTION The intake valves (1) are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The exhaust valves are made of iron alloys (2). The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (2). The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs Valve: Service and Repair Removal - Valve Springs REMOVAL - VALVE SPRINGS 1. Disconnect the battery negative cables. 2. Remove the cylinder head cover. 3. Disconnect the injector harness connectors at cylinder head cover gasket. Remove all injector solenoid nuts. Remove cylinder head cover gasket. 4. Remove injector(s) for cylinder(s) to be serviced. 5. Remove the rocker housing. 6. Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position. 7. Using the crankshaft barring tool # 7471-B (2), rotate the engine to position the damper mark in the 12 o'clock position. At this engine position, cylinders #1 and #6 can be serviced. 8. Remove the accessory drive belt. 9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover. 10. Divide the crankshaft damper into three equally sized segments as follows: a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by three (3). b. Measure that distance in a counterclockwise direction from the first balancer mark and place another mark on the balancer. c. From the second damper mark, again measure in a counterclockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock position. d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2938 11. Compress the valve springs at cylinders. #1 and #6 as follows: a. Install the valve spring compressor mounting base as shown in. b. Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clockwise) to compress the valve springs and remove the collets. c. Rotate the compressor nut counterclockwise to relieve tension on springs. Remove spring compressor. d. Remove and replace retainers, springs, and seals as necessary. e. Do not rotate the engine until the springs and retainers are reinstalled. f. Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets. g. Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer. 12. Using the crankshaft barring tool (2), rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #2 and #5 can be serviced. 13. Repeat the valve spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. 14. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #3 and #4 can be serviced. 15. Repeat the spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2939 Valve: Service and Repair Installation INSTALLATION 1. Install rocker housing. 2. Install fuel injectors and high pressure fuel lines. 3. Lubricate the valve tips and install the crossheads in their original locations. 4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 5. Verify valve lash adjustment. 6. Install cylinder head cover gasket onto rocker housing. 7. Install injector solenoid nuts. 8. Connect injector harness connectors. 9. Install cylinder head cover. 10. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2940 Valve: Service and Repair Valves, Guides And Springs VALVES, GUIDES AND SPRINGS REMOVAL 1. Remove cylinder head. 2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench. 3. Install the valve spring compressor mounting base (1) as shown. 4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks. 5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2941 6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations. 7. Repeat the procedure on all cylinders to be serviced. CLEANING Clean the valve stems with crocus cloth or a Scotch-Brite(TM) pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air. INSPECTION Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent. Measure the valve stem diameter in three places as shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2942 Valve Guide Bore Specifications Measure the cylinder head valve guide bore. Measure valve margin (rim thickness). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2943 Measure the valve spring free length and maximum inclination. Test valve spring force with tool C-647 (1). Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.). INSTALLATION 1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves. 2. Install the valves in their original position. The exhaust valves are identified by a dimple on the valve head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 2944 3. Install the valve (2), springs (4), and retainer (5). 4. Install the valve spring compressor tool 8319-A (1) as shown. 5. Compress the valve springs and install the valve retaining locks. 6. Remove the compressor and repeat the procedure on the remaining cylinders. 7. Install new o-ring and sealing washer on injector. 8. Lubricate o-ring and injector bore. 9. Verify sealing washer (shim) was removed with old injector. 10. Install injector. 11. Install the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2949 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2950 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2951 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. 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 ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2952 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2953 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2956 Drive Belt: Removal and Replacement Removal 5.9L/6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a 1/2 inch drive-long handle ratchet to this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate ratchet and tensioner assembly clockwise (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 5.9L/6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2957 Belt Routing - DIESEL WITH 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. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 1/2 inch ratchet to tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate ratchet and belt tensioner clockwise. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description Drive Belt Tensioner: Description and Operation Description DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description > Page 2962 Drive Belt Tensioner: Description and Operation Operation OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal Drive Belt Tensioner: Service and Repair Removal 5.9L/6.7L DIESEL WARNING: Because of high spring pressure, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly. 1. Remove accessory drive belt. 2. Remove tensioner mounting bolt and remove tensioner (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal > Page 2965 Drive Belt Tensioner: Service and Repair Installation 5.9L/6.7L DIESEL 1. Install tensioner assembly (7) to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 Nm (32 ft. lbs.) torque. 2. Install drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount Removal REMOVAL CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Disconnect the battery negative cables. 2. Remove the viscous fan/drive assembly. 3. Raise vehicle on hoist. 4. Install engine support fixture tool #8534 and steel bracket tool #8534A 5. Loosen the thru-bolt and nut. 6. Lift the engine SLIGHTLY and remove the insulator to block bolts. 7. Remove the RH mount (2) from the engine. 8. Remove the LH insulator (2) from the vehicle. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2970 CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. With engine raised SLIGHTLY, position the LH insulator (2) to the mount. Install the bolts and torque to specification. 2. With engine raised SLIGHTLY, position the RH insulator (2) to the mount. Install the bolts and torque to specification. 3. Lower the engine using tool #8534, while guiding the mount and thru-bolt into the frame mounted support cushion brackets. 4. Install the thru bolt nut and tighten the nut to 95 Nm (70 ft. lbs.) torque. 5. Remove the engine support fixture tool #8534. 6. Lower the vehicle. 7. Install the viscous fan/drive assembly. 8. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2971 Engine Mount: Service and Repair Rear Mount Removal REMOVAL CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Raise the vehicle on a hoist. 2. Position a transmission jack in place. 3. Remove support cushion stud nuts (6). 4. Raise rear of transmission until cushion studs (6) clear frame. 5. Remove the nuts holding the support cushion (5) to the transmission support bracket (8). 6. Remove support cushion (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2972 7. Remove the bolts (3) holding the transmission support to the bracket (4). 8. Remove the bolts (7) holding the transmission support to the transmission. 9. Remove the transmission support (8). 10. Remove the nuts (1) from the transmission bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2973 11. Remove the bracket (3) from the transmission. Installation INSTALLATION CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. If removed, position the brackets to the transmission. Install attaching fasteners (1, 2), Do not tighten at this time.. 2. Position support cushion (5) to transmission support bracket (3). Install stud nuts (4) and tighten to 61 Nm (45 ft. lbs.) torque. 3. Position assembled support cushion (5) and bracket (3) to transmission. 4. Install the support bracket bolt (7) and tighten to 54 Nm (40 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2974 5. Install the support bracket bolts (3) and tighten to 50 Nm (37 ft. lbs.) torque. 6. Torque the bracket to transmission nuts (11) to 30 Nm (22 ft. lbs.) torque. 7. Using the transmission jack, lower the transmission and support cushion (5) onto the crossmember. 8. Install the support cushion nuts (6) and tighten to 61 Nm (45 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2975 9. Remove the transmission jack. 10. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2980 Engine Oil Pressure: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE 1. Remove the 1/8 npt plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to ENGINE - TESTING. 5. Remove oil pressure gauge and install the 1/8 npt plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2985 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ................................................. 11.4Liters (12.0 Qt) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2988 Engine Oil: Fluid Type Specifications ENGINE OIL - DIESEL ENGINES Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ-4/SM (5.9L), or CJ-4 (6.7L), or higher that meets Cummins CES 20081 Standards. Low ash diesel engine oil is REQUIRED for the 6.7L engine, use MOPAR® MaxPro 15W-40 6700 Diesel DPF diesel engine oil, or equivalent. SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 15W-40 engine oils that meet Chrysler material standard MS-10902, be used in accordance to ACEA B3, B4 specification. European Grade 15W-40 oils that meet Association des Constructeurs Europe■ens d' Automobiles (European Automobile Manufacturers Association) (ACEA) specifications, are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15°C (5°F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2989 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2990 Engine Oil: Service and Repair ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. NOTE: Change engine oil and filter at intervals specified in the owner's manual. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter. 5. Install new oil filter. 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. 9. Fill the engine with the correct grade of new oil. 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair > Procedures Engine Oil Control Valve: Procedures Cleaning CLEANING 1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine. Inspection INSPECTION Inspect the plunger and plunger bore for cracks and excessive wear. Polished surfaces are acceptable. Verify that the plunger moves freely in the bore. Check the spring for height and load limitations. Replace the spring if out of limits shown in the figure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair > Procedures > Page 2995 Engine Oil Control Valve: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the threaded plug (2), spring (4) and valve (5). Insert a finger or a seal pick to lift the plunger from the bore. NOTE: If the plunger is stuck in the bore, it will be necessary to remove the filter head. Installation INSTALLATION 1. Install the plunger, spring, and plug as shown in. Tighten the plug to 80 Nm (59 ft. lbs.) torque. 2. Connect the battery negative cables. 3. Start the engine and verify that it has oil pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures Oil Cooler: Procedures CLEANING AND INSPECTION Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures > Page 3000 Oil Cooler: Removal and Replacement Removal REMOVAL - OIL COOLER 1. Disconnect Negative battery cables. 2. Drain Coolant. 3. Disconnect Ambient Air and MAF Sensors on Air Filter housing. 4. Loosen hose clamp at Turbocharger Inlet. 5. Move clamp on Engine Breather hose at Inlet elbow at turbocharger and remove hose. 6. Remove Air Filter housing cover and inlet hose and set aside. 7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. 8. Loosen the three clamps and hoses from the Coolant outlet tube. 9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm). 10. Remove Coolant outlet tube. 11. Loosen turbocharger oil supply hose from oil cooler housing. 12. Remove oil filter. 13. Loosen and remove the 14 oil cooler attachment capscrews (10 mm). 14. Remove oil cooler housing and oil cooler from engine block. Installation INSTALLATION 1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material 2. Using new gaskets install oil cooler, oil cooler housing to cylinder block. NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine damage. 3. Tighten mounting capscrews in a criss-cross pattern. Torque to 24 Nm (18 ft-lb) 4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18 ft-lb) 5. Connect tube to hoses and secure with hose clamps 6. Swing generator into place and torque through bolts to specs. 7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place 8. Tighten hose clamp at Turbocharger to specs. 9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place. 10. Connect Ambient Air and MAP sensors. 11. Fill Engine with coolant. 12. Connect battery cables. 13. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3001 Oil Cooler: Tools and Equipment 1/2" Oil Cooler Line Rem. AST tool# 8016 Used for removing both of the oil cooler lines from the fittings on automatic transmission and oil coolers. - Used for R and R of Oil and Transmission Cooler Lines - Green-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3002 8107 - 7-Piece Line Disconnect Set 8110 - 10-Pc. Line Disconnect Set Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 3007 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Procedures Oil Line: Procedures CLEANING AND INSPECTION Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Procedures > Page 3012 Oil Line: Removal and Replacement Removal REMOVAL - OIL COOLER 1. Disconnect Negative battery cables. 2. Drain Coolant. 3. Disconnect Ambient Air and MAF Sensors on Air Filter housing. 4. Loosen hose clamp at Turbocharger Inlet. 5. Move clamp on Engine Breather hose at Inlet elbow at turbocharger and remove hose. 6. Remove Air Filter housing cover and inlet hose and set aside. 7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. 8. Loosen the three clamps and hoses from the Coolant outlet tube. 9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm). 10. Remove Coolant outlet tube. 11. Loosen turbocharger oil supply hose from oil cooler housing. 12. Remove oil filter. 13. Loosen and remove the 14 oil cooler attachment capscrews (10 mm). 14. Remove oil cooler housing and oil cooler from engine block. Installation INSTALLATION 1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material 2. Using new gaskets install oil cooler, oil cooler housing to cylinder block. NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine damage. 3. Tighten mounting capscrews in a criss-cross pattern. Torque to 24 Nm (18 ft-lb) 4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18 ft-lb) 5. Connect tube to hoses and secure with hose clamps 6. Swing generator into place and torque through bolts to specs. 7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place 8. Tighten hose clamp at Turbocharger to specs. 9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place. 10. Connect Ambient Air and MAP sensors. 11. Fill Engine with coolant. 12. Connect battery cables. 13. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan-Bolts ........................................................................................................................................ .................................................... 28 Nm (21 ft. lbs.) NOTE: Start in the center and work outward. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures Oil Pan: Procedures Cleaning CLEANING Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent. Inspection INSPECTION Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component. Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3018 Oil Pan: Removal and Replacement Removal REMOVAL 4x4 1. Open the hood. 2. Disconnect the battery negative cables. 3. Remove the intake air assembly. 4. Remove the radiator shroud retaining bolts. 5. Install engine support fixture # 8534B. 6. Raise and support the vehicle. WARNING: HOT OIL CAN CAUSE PERSONAL INJURY. 7. Drain the engine oil. 8. Loosen the front engine mount bolts. 9. Lower the vehicle. 10. Use the engine support fixture #8534B to raise engine out of the front mounts. 11. Remove the engine oil dipstick. 12. Raise and support the vehicle. 13. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners. 14. Remove oil pan and suction tube. 15. Remove the 2 bolts from the front of the engine block stiffener. 16. Remove the oil pan. 4x2 1. Open the hood. 2. Remove the negative battery cables. 3. Raise and support the vehicle. 4. Remove the transmission oil cooler lines. 5. Remove the propeller shaft. 6. Remove the starter bolts. 7. Support the starter. 8. Remove the torque converter bolts. 9. Remove the exhaust hanger bolts. 10. Remove the gear shift cable. 11. Remove the wiring harness. 12. Remove the transmission mount. 13. Remove the crossover bolts. 14. Position the transmission jack. 15. Remove the bell housing bolts. 16. Remove the transmission. 17. Remove the flywheel housing bolts (8). 18. Remove the flex plate bolts (8). 19. Remove the engine oil dip stick. 20. Drain the oil. 21. Remove the steering rack bolts. 22. Remove the oil pan bolts. 23. Remove the oil pickup bolts. 24. Remove the oil pan. Installation INSTALLATION 4x4 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3019 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the engine oil dipstick. 9. Install the engine block stiffener. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Lower vehicle. 12. Lower the engine into the motor mounts and tighten the through bolts to 88 Nm (64 ft. lbs.). 13. Install battery negative cables. 14. Fill the crankcase with new engine oil. 15. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary. 16. Remove the engine support fixture #8534B. 17. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 18. Fill the engine oil. 19. Connect the battery negative cables. 20. Close the hood. 4x2 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the steering rack bolts. 9. Install the flex plate. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Install transmission and transfer case (if equipped). 12. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 Nm (57 ft. lbs.) torque. NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the EGR cooler. 14. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 15. Remove the transmission jack. 16. Install the crossmember bolts. 17. Install the transmission mount. 18. Install the wiring harness. 19. Install the gear shift cable. 20. Install the exhaust hanger bolts. 21. Install the torque converter bolts. 22. Install the starter. 23. Install the starter bolts. 24. Install the transmission oil cooler lines. 25. Connect the negative battery cables. 26. Close the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3024 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3028 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3029 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3030 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3031 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3032 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3033 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3034 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3035 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3036 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 3039 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3066 Engine Oil Pressure: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE 1. Remove the 1/8 npt plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to ENGINE - TESTING. 5. Remove oil pressure gauge and install the 1/8 npt plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold capscrews to .............................................................................................................. ..................................................... 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Cleaning CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). Inspection INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 3072 Intake Manifold: Removal and Replacement Removal REMOVAL 1. Disconnect the batteries. 2. Disconnect the EGR air Transfer tube temperature sensor. 3. Disconnect the EGR Valve Actuator Connector 4. Disconnect the Engine Oil level tube at the Air Inlet bracket 5. Loosen the CAC Outlet tube clamps at the CAC Outlet and Air Inlet and remove the tube. 6. Loosen and remove both v-band clamps at each end of the Air Transfer tube 7. Remove the P-clip mounting capscrew 8. Remove the Air Transfer tube 9. Loosen and remove six (6) Air Inlet mounting capscrews. 10. Remove the air inlet. 11. Remove the injector fuel lines. 12. Disconnect the Fuel Rail Pressure sensor at the rear of the fuel rail manifold. 13. Remove the High Pressure fuel line from the dump/overflow valve. 14. Remove the fuel rail. 15. Remove the grid heater wiring connector. 16. Disconnect the TMAP sensor. 17. Remove the intake manifold capscrews. 18. Remove the intake manifold. Installation INSTALLATION 1. Clean the Intake Manifold and Cylinder Head Gasket area. 2. Install a new intake manifold gasket. 3. Position the intake manifold and Install the intake manifold capscrews finger tight. 4. Position the fuel rail and install the fuel rail manifold capscrews finger tight. 5. Torque the intake manifold capscrews to 24 N.m (18 ft. lbs.). 6. Connect the fuel rail pressure sensor. 7. Connect the intake manifold grid heater. Torque the capscrew to 10 N.m (89 in. lbs.). 8. Install the fuel lines. 9. Torque the fuel rail mounting capscrews to 24 N.m (18 ft. lbs.). 10. Clean the Air Inlet gasket area. 11. Clean the Intake Manifold to air inlet area. 12. Install the new Air Intake connection gasket. 13. Install the air intake connection to the intake manifold 14. torque the intake manifold to 24 N.m (18 lbs. ft.). 15. Install the Oil Level Gauge tube and torque to 24 N.m (18 lbs. ft.). 16. Clean the gasket area of the Air Transfer Tube (both ends). 17. Clean the EGR cooler and EGR control valve gasket area. 18. Using new gaskets, install the Air Transfer Tube. 19. Install the V-band clamps. 20. Install the P-clip to the bracket. Torque the mounting capscrew to 24 N.m (18 lbs. ft.). 21. Torque the V-band clamps to 10 N.m (89 lbs. in.). 22. Connect the EGR Valve Actuator connector. 23. Connect the EGR Gas Temperature connector. 24. Connect the batteries. 25. Start the engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3078 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the transmission and transfer case (if equipped). 3. Remove the clutch cover and disc (if manual transmission equipped). 4. Remove the flywheel or converter drive plate. 5. Remove the flywheel adapter plate. 6. Drill holes 180° apart into the seal. Be careful not to contact the drill against the crankshaft. 7. Install #10 sheet metal screws (1) in the drilled holes and remove the rear seal with a slide hammer (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 3084 Crankshaft Main Bearing Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel. 2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket. 3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft. 4. Remove the seal pilot. 5. Install the installation tool over crankshaft. 6. Using a ball peen hammer, strike the tool (2) at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer. NOTE: Always install a new clamping ring, never reuse the old clamping ring. 7. Install the flywheel or converter drive plate, and clamping ring. Tighten the bolts to 137 Nm (101 ft. lbs.) torque. 8. Install the clutch cover and disc (if equipped). 9. Install the transmission and transfer case (if equipped). 10. Lower vehicle. 11. Connect battery negative cables. 12. Check engine oil level and adjust, if necessary. 13. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal Front Crankshaft Seal: Service and Repair Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud. 8. Remove viscous fan/drive assembly. 9. Remove cooling fan shroud and fan assembly from the vehicle. 10. Remove the accessory drive belt. 11. Remove the cooling fan support/hub from the front of the engine. 12. Raise the vehicle on hoist. 13. Remove the crankshaft damper. 14. Remove power steering pump. 15. Remove accessory drive belt tensioner. 16. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Remove crank seal dust shield with cover. 17. Support the cover on a flat work surface with wooden blocks, and using a suitable punch (1) and hammer, drive the old seal out of the cover from the back side of the cover to the front side. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3089 Front Crankshaft Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free of all oil residue, to prevent leaks. The crankshaft and seal surface must be completely dry when the seal is installed. 1. Clean cover and housing gasket mating surfaces. Use a suitable scraper and be careful not to damage the gear housing surface. Remove any old sealer from the oil seal bore. Thoroughly clean the front seal area of the crankshaft. Do not sand this surface. The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. 2. Inspect the gear housing and cover for cracks and replace if necessary. Carefully straighten any bends or imperfections in the gear cover with a ball-peen hammer on a flat surface. Inspect the crankshaft front journal for any grooves or nicks that would affect the integrity of the new seal. 3. Apply a bead of Mopar(R) Stud & Bearing Mount to the outside diameter of the seal. Do not lubricate the inside diameter of the new seal. 4. With the cover supported by wood blocks, install the seal into the rear of the cover using crankshaft seal installer Special Tool 8281 and driver handle C-4171. Strike the driver handle until the installation tool bottoms out on the inside of the cover. CAUTION: Do not distort or damage seal. 5. Install the plastic seal pilot (provided with seal kit) into the crankshaft seal. 6. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing surface. 7. Install the cover to the gear housing, aligning the seal pilot with the nose of the crankshaft. NOTE: Failure to follow the cover installation procedure can result in misalignment of the crankshaft seal to the crankshaft, causing an oil leak. 8. Install the cover bolts and hand snug 2 capscrews at the 3 o'clock and 9 o'clock position, to keep the cover from moving when the first capscrew is torqued. Torque to 24 Nm (18 ft. lbs.) torque. Remove pilot tool. 9. Install dust shield over nose of crankshaft. 10. Install the crankshaft damper. Torque the bolts to 40 Nm (30 ft. lbs.). Then rotate an additional 60°. Use the engine barring tool to keep the engine from rotating during tightening operation. 11. Install the fan support/hub assembly and torque bolts to 32 Nm (24 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3090 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft.lbs.). 14. Install cooling fan. 15. Install the accessory drive belt. 16. Refill cooling system. 17. Connect battery negative cables. 18. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal Oil Pan Gasket: Service and Repair Removal REMOVAL 1. Disconnect the battery. 2. Remove the intake air assembly. 3. Remove the inner radiator shroud retaining bolts. 4. Remove the inner radiator shroud. 5. Raise and support the vehicle. 6. Remove the front suspension rear tie bar. 7. Remove the left engine mount through bolt. 8. Remove the right engine mount through bolt. 9. Remove the rack and pinion retaining bolts. 10. Drain the engine oil. 11. Lower the vehicle. 12. Install the engine lift fixture. 13. Use the engine lift fixture to raise the engine. 14. Raise the vehicle on the hoist. 15. Remove the oil pan retaining bolts. 16. Lower the oil pan enough to allow the removal of the oil pan gasket. 17. Remove the oil pan gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal > Page 3095 Oil Pan Gasket: Service and Repair Installation INSTALLATION 1. Clean the oil pan gasket surfaces to be sure the surfaces are free of debris and oil. 2. Install a new oil pan gasket. 3. Install the oil pan bolts in a cross pattern. 4. Install the rack and pinion bolts. 5. Lower the vehicle. 6. Lower the engine into the mounts. 7. Remove the engine lift fixture. 8. Fill the engine with oil. 9. Raise and support the vehicle. 10. Install the left engine mount through bolt. 11. Install the right engine mount through bolt. 12. Install the front suspension rear tie bolts. 13. Lower the vehicle. 14. Install the radiator shroud. 15. Install the radiator shroud bolts. 16. Install the intake air assembly. 17. Connect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3100 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3101 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3102 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3103 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3104 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3105 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3106 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3107 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3108 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 3111 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Install the camshaft. Align the crankshaft and camshaft gear marks as shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front Timing Cover: Service and Repair Case - Front Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Remove viscous fan/drive/shroud assembly. 8. Remove the accessory drive belt. 9. Remove the cooling fan support/hub from the front of the engine. 10. Raise the vehicle on hoist. 11. Remove the crankshaft damper. 12. Remove the lower fan shroud bracket. 13. Remove the upper fan shroud bracket that is mounted to the gear housing. 14. Lower the vehicle. 15. Remove the power steering pump. 16. Remove the accessory drive belt tensioner. 17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. 18. Remove the fuel injection pump. 19. Disconnect the camshaft position sensor connector. 20. Disconnect and remove engine speed sensor. 21. Remove the camshaft. 22. Remove the six front oil pan fasteners. 23. Remove the gear housing fasteners. NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged. 24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal. 25. Remove the gear housing and gasket. 26. Clean the gasket material from the cylinder block and gear housing. Installation INSTALLATION 1. Inspect oil pan gasket. If torn, gasket must be replaced. 2. Install a new gear housing gasket onto cylinder block and trim any excess gasket material flush to oil pan rail. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front > Page 3143 3. Place a small amount of Mopar(R) engine RTV to the corners of the block and pan gasket T-joint to ensure a good seal. 4. Install the gear housing. Torque bolts to 24 Nm (18 ft. lbs.). 5. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing. 6. Connect the camshaft position sensor connector. 7. Install and connect engine speed sensor. 8. Install the injection pump. 9. Install the camshaft. Align the crankshaft and camshaft gear marks as shown. 10. Install a new front crankshaft seal into the gear cover. 11. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 12. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft lbs). 13. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This center's the seal on the crankshaft. 14. Tighten the bolt to 24 Nm (18 ft. lbs.) torque in a circular pattern. 15. Remove the seal pilot. Install front seal dust shield. 16. Raise the vehicle. 17. Install the crankshaft damper. Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. 18. Install the lower fan shroud bracket. Torque bolts to 24 Nm (18 ft. lbs.) torque. 19. Install the upper fan shroud brackets. Hand tighten only. 20. Lower vehicle. 21. Install the fan support/hub assembly and tighten bolts to 32 Nm (24 ft. lbs.) torque. 22. Install the power steering pump. 23. Install the accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 24. Install the accessory drive belt. 25. Install the upper cooling fan/drive/shroud assembly. 26. Torque the upper fan shroud brackets to 24 Nm (18 ft. lbs.) torque. 27. Connect the coolant recovery bottle hose to the radiator filler neck. 28. Install the radiator upper hose and clamps. 29. Add engine oil. 30. Add coolant. 31. Connect the battery cables. 32. Start engine and inspect for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front > Page 3144 Timing Cover: Service and Repair Cover - Timing Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Remove viscous fan/drive/shroud assembly. 7. Remove the accessory drive belt. 8. Remove the cooling fan support/hub from the front of the engine. 9. Raise the vehicle on hoist. 10. Remove power steering pump. 11. Remove accessory drive belt tensioner. 12. Remove the crankshaft damper. 13. Lower the vehicle. 14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Installation INSTALLATION 1. Install a new front crankshaft oil seal. 2. Obtain a seal pilot (1) installation tool from a crankshaft front seal service kit and install the pilot into the seal. 3. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 4. Using the seal pilot to (1) align the cover , install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft. lbs). 5. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This centers the seal on the crankshaft. 6. Tighten the bolts to 24 Nm (18 ft. lbs.) in a circular pattern. 7. Remove the seal pilot. Install front seal dust shield. 8. Raise the vehicle. 9. Install the crankshaft damper. 10. Lower vehicle. 11. Install the fan support/hub assy, and tighten bolts to 32 Nm (24 ft. lbs.) torque. 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 14. Install the accessory drive belt. 15. Install the cooling fan/drive/shroud assembly. 16. Install the radiator upper hose and clamps. 17. Add coolant. 18. Connect the battery cables. 19. Start engine and inspect for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3151 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3152 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3153 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3162 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3163 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3168 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3169 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 3172 Fuel Filter: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3175 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3176 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3177 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3178 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3179 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3189 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION 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). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, 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 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 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 3193 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, 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. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Install water pump with the weep hole facing downward. Tighten mounting bolts to ............................................................................. 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump Description WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump > Page 3199 Water Pump: Description and Operation Water Pump Bypass Description WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. Operation - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 3200 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3203 Water Pump: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system. 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. 5. Remove generator assembly. 6. Remove the accessory drive belt. 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Installation 5.9L/6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3204 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt. 5. Install air box and tube assembly. 6. Install air filter housing. 7. Fill cooling system. 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3210 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................ 22.6 qts (21.4L) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3213 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description Coolant COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year 100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. 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% 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. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of 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 or freeze-up on a cooling system designed for ethylene-glycol. Propylene- glycol also has poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene-glycol. HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 3216 Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. 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 specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37 °C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 3217 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 3218 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 3223 Coolant Reservoir: Description and Operation Operation OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal Coolant Reservoir: Service and Repair Removal 5.9L/6.7L DIESEL 1. Remove overflow hose (5) from radiator (1) 2. Remove mounting bolts (4). 3. Remove coolant recovery bottle (2) from bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal > Page 3226 Coolant Reservoir: Service and Repair Installation 5.9L/6.7L DIESEL 1. Position coolant recovery bottle (2) on bracket (3). 2. Install mounting bolts (4). Tighten to 8.5 Nm (75 in. lbs). 3. Install overflow hose (5) onto radiator (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3231 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3232 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3233 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3234 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3235 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 3263 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 3266 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description > Page 3271 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation > Page 3274 Heater Core: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3280 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines] and the high end of normal about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description Radiator: Description and Operation Description DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description > Page 3285 Radiator: Description and Operation Operation OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 3286 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: Hot, pressurized coolant can cause injury by scalding. Using a rag to cover the radiator pressure cap, open 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 filler neck. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Cleaning CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. Inspection INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3289 Radiator: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect both battery negative cables. WARNING: Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur. 2. Drain the cooling system. 3. Disconnect ambient air temperature sensor electrical connector and mass airflow sensor electrical connector (If equipped). 4. Remove air box and turbocharger inlet tube. 5. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator. 6. Remove hose clamps and hoses from radiator. 7. Remove fan shroud mounting nuts from mounting brackets. 8. Pull shroud toward front of vehicle to clear mounting brackets 9. Turn shroud slightly and push toward engine to gain clearance for radiator. 10. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way. 11. Disconnect the transmission cooler lines at the transmission cooler. The transmission cooler will remain on the radiator and can be removed as an assembly. 12. Remove the two radiator upper mounting bolts. 13. Tilt radiator toward front of vehicle and lift out of engine compartment. The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower radiator support panel. Rubber biscuits (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser or the electronic viscous fan connector when removing. Installation 5.9L/6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3290 1. Install rubber insulators to alignment dowels at lower part of radiator. 2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application. 3. Install two upper radiator mounting bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 4. Connect both radiator hoses and install hose clamps. 5. If equipped, connect transmission cooler lines to transmission cooler. Inspect quick connect fittings for debris and install until an audible "click" is heard. Tug on lines to verify connection. 6. Position power steering cooler on the radiator and tighten nuts to 10 Nm (90 in. lbs.) 7. Position fan shroud on brackets. 8. Install fan shroud mounting nut. Tighten nut to 24 Nm (18 ft. lbs.). 9. Install the coolant recovery container. 10. Position coolant recovery tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator. 11. Install air box and turbocharger inlet hose. Tighten clamps to 4 Nm (35 in. lbs.). 12. Connect mass airflow sensor electrical connector and ambient air temp sensor electrical connector (if equipped). 13. Position heater controls to full heat position. 14. Fill cooling system with coolant. 15. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description Radiator Cap: Description and Operation Description DESCRIPTION All cooling systems are equipped with a pressure cap. For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description > Page 3295 Radiator Cap: Description and Operation Operation OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap Radiator Cap: Testing and Inspection Radiator Cap RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap > Page 3298 Radiator Cap: Testing and Inspection Radiator Cap To Filler Neck Seal RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: The warning words, "DO NOT OPEN HOT", on radiator pressure cap, are a safety precaution. When hot, pressure builds up in cooling system. To prevent scalding or injury, radiator cap should not be removed while system is hot and/or under pressure. Do not remove the radiator cap at any time except for the following purposes: - Check and adjust antifreeze freeze point. - Refill the system with new antifreeze. - Conducting service procedures. - Checking for vacuum leaks. WARNING: If vehicle has been run recently, wait at least 15 minutes before removing radiator cap. With a rag, squeeze radiator upper hose to check if system is under pressure. Place a rag over cap and without pushing cap down, rotate it counter-clockwise to first stop. Allow fluid to escape through the coolant reserve/overflow hose into reserve/overflow tank. Squeeze radiator upper hose to determine when pressure has been released. When coolant and steam stop being pushed into tank and system pressure drops, remove radiator cap completely. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning Radiator Cap: Service and Repair Cleaning CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning > Page 3301 Radiator Cap: Service and Repair Inspection INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3306 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3307 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3308 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3309 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3310 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 3317 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 3320 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3325 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines] and the high end of normal about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications The thermostat will begin to open at 85.5 - 89.4°C (186 - 193°F). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3329 Thermostat: Description and Operation DIESEL CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. An engine with the thermostat removed will operate in the radiator bypass mode, causing an overheat condition. The thermostat of the diesel engine is located in the front of the cylinder head, underneath a heat shield near the thermostat housing. NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat will cause overheating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > On-Board Diagnostics Thermostat: Testing and Inspection On-Board Diagnostics ON-BOARD DIAGNOSTICS All models are equipped with On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD). If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the scan tool. Refer to the appropriate Powertrain Diagnostic Procedures information for diagnostic information and operation of the scan tool. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > On-Board Diagnostics > Page 3332 Thermostat: Testing and Inspection Diesel Engine DIESEL ENGINE The cooling system used with the diesel engine provides the extra coolant capacity and extra cooling protection needed for higher GVWR (Gross Vehicle Weight Rating) and GCWR (Gross Combined Weight Rating) vehicles. This system capacity will not affect warm up or cold weather operating characteristics if the thermostat is operating properly. This is because coolant will be held in the engine until it reaches the thermostat "set" temperature. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower temperature gauge readings for diesel versus gasoline engines may, at times be normal. Typically, complaints of low engine coolant temperature are observed as low heater output when combined with cool or cold outside temperatures. To help promote faster engine warm-up, the electric engine block heater must be used with cool or cold outside temperatures. This will help keep the engine coolant warm when the vehicle is parked. A "Cold Weather Cover" is available from the parts department through the Mopar Accessories product line. This accessory cover is designed to block airflow entering the radiator and engine compartment to promote faster engine warm-up. It attaches to the front of the vehicle at the grill opening. The cover is to be used with cool or cold temperatures only. If used with high outside temperatures, serious engine damage could result. Refer to the literature supplied with the cover for additional information. For engines equipped with exhaust brakes, this device can be used to aid engine warm-up while the engine is idling. 1. To determine if the thermostat is defective, it must be removed from the vehicle. 2. After the thermostat has been removed, examine the thermostat and inside of thermostat housing for contaminants. If contaminants are found, the thermostat may already be in a "stuck open" position. Flush the cooling system before replacing thermostat. 3. Place the thermostat into a container filled with water. 4. Place the container on a hot plate or other suitable heating device. 5. Place a commercially available radiator thermometer into the water. 6. Apply heat to the water while observing the thermostat and thermometer. 7. The thermostat will begin to open at 85.5 - 89.4°C (186 - 193°F). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal Thermostat: Service and Repair Removal 6.7L DIESEL ENGINE WARNING: Do not loosen the radiator draincock with the system hot and pressurized. Serious burns from the coolant can occur. 1. Disconnect the battery negative cables. 2. Drain cooling system until coolant level is below thermostat. 3. Disconnect exhaust gas pressure sensor electrical connector (3). 4. Remove exhaust pressure tube (4) from thermostat housing. 5. Remove EGR cooler cross over tube (1). 6. Remove radiator hose clamp and hose from thermostat housing (1). 7. Remove heat shield. 8. Remove the three water outlet-to-cylinder head bolts (5) and remove the water outlet connector. 9. Clean the mating surfaces of the thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 3335 Thermostat: Service and Repair Installation 6.7L DIESEL ENGINE NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. 1. Inspect thermostat seal for cuts or nicks. Replace if damaged. 2. Install the thermostat into the groove in the top of the cylinder head. 3. Install the thermostat housing and bolts (5). Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install heat shield. Tighten bolts to 9 Nm (79 in. lbs.). 5. Install exhaust pressure tube (4). Tighten to 10 Nm (88 in. lbs.). 6. Connect exhaust pressure sensor electrical connector (2). 7. Install EGR cross over tube (1). 8. Install P-clip and bolt. Tighten to 8 Nm (70 in. lbs.). 9. Install the radiator upper hose and clamp. 10. Fill the cooling system with coolant. 11. Connect the battery negative cables. 12. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Install water pump with the weep hole facing downward. Tighten mounting bolts to ............................................................................. 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump Description WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump > Page 3341 Water Pump: Description and Operation Water Pump Bypass Description WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. Operation - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 3342 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3345 Water Pump: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system. 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. 5. Remove generator assembly. 6. Remove the accessory drive belt. 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Installation 5.9L/6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3346 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt. 5. Install air box and tube assembly. 6. Install air filter housing. 7. Fill cooling system. 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3353 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3354 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3355 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3356 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3357 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3358 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3359 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3360 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3363 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3364 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3365 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3366 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3367 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3368 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3369 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3370 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3373 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3376 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 3383 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3392 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3393 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3399 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3400 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The diesel oxidation catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC/Diesel Particulate Filter (DPF) assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. DIESEL PARTICULATE FILTER The diesel particulate filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 3403 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 3404 Diesel Particle Filter (DPF): Testing and Inspection DIAGNOSIS AND TESTING - DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to - ENGINE Testing. See: Engine/Testing and Inspection/Component Tests and General Diagnostics Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB-CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate. 7. 4X4 Vehicles - Remove transmission crossmember. 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3407 Diesel Particle Filter (DPF): Service and Repair Removal - P/U 6.7L DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Loosen and remove DPF differential pressure tubes (4 and 6). 4. Disconnect and remove temperature sensor (2). 5. 4X4 Vehicles - Remove transfer case skid plate. 6. 4X4 Vehicles - Remove transmission crossmember. 7. Remove DPF to muffler clamp (5). Discard clamp. 8. Move muffler and tail pipe assembly toward rear of vehicle. 9. Remove DPF to catalytic converter flange nuts. 10. Remove DPF. Discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3408 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB-CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten torque clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember. 11. 4X4 Vehicles - Install transfer case skid plate. 12. Connect electrical connectors. 13. Connect negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3409 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U 1. Position new exhaust flange gaskets on catalytic converter to DPF flange. 2. Install flange bolts. Hand tighten only. 3. Install muffler and tailpipe assembly 4. Install new band clamp. Hand tighten only. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Tighten flange nuts to 54 Nm (40 ft. lbs) 7. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 8. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 9. Install front and rear (6 and 4) exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 10. Install flexible exhaust differential pressure sensor tubing. 11. 4X4 Vehicles - Install transmission crossmember. 12. 4X4 Vehicles - Install transfer case skid plate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations Exhaust Brake Switch: Locations Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3414 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3415 Exhaust Brake Switch: Diagrams Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3416 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Starting from the center and moving in a pattern outward, torque the exhaust manifold bolts to ............................................................. 43 Nm (32 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Cleaning CLEANING Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite(TM) pad or equivalent. Inspection INSPECTION Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20 mm (.008 inch). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3422 Exhaust Manifold: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Drain the coolant. See: Cooling System/Service and Repair 3. Raise vehicle on hoist. 4. Remove the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 5. Remove the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 6. Remove the air filter inlet hose from the turbo inlet. 7. Remove the delta-P line bracket capscrew nuts and remove the delta-P line from the exhaust manifold and thermostat housing. 8. Remove the heat shield and noise panel (if equipped) from the exhaust manifold. 9. Remove the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 10. Remove the two (2) rear exhaust manifold capscrew lock plates. 11. Remove the Cab Heater tubing/bracket from the exhaust manifold stud. 12. Remove the exhaust manifold. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3423 1. Clean the exhaust manifold gasket surfaces. 2. Clean the cylinder head exhaust port gasket surfaces. 3. Clean the turbo mounting flange on the exhaust manifold. 4. Clean the turbo mounting flange on the turbocharger. 5. Install the exhaust manifold to turbocharger gasket and capscrews. 6. Install the exhaust manifold gasket. NOTE:The five exhaust manifold capscrews with studs are used at the No.1 and No.2 cylinder locations for the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket. 7. Install the exhaust manifold spacers and capscrews. 8. Starting from the center and moving in a pattern outward, tighten the exhaust manifold bolts to 43 N-m (32 ft. lbs.) 9. Install the exhaust manifold capscrew lock plates. 10. Install the exhaust manifold heat shields/noise panels. Tighten the mounting nuts to 24 N-m (18 ft. lbs.). 11. Install the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 12. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat capscrews. 13. Tighten the delta-P line bracket nut to 24 N-m (18 ft. lbs.). 14. Tighten the delta-P line bracket bolt to 10 N-m (89 in. lbs.). 15. Tighten the delta-P flare nuts to 10 N-m (89 in. lbs.). 16. Install the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 17. Install the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 18. Fill the coolant. See: Cooling System/Service and Repair 19. Connect the battery negative cables. 20. Start the engine to check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust Exhaust Pipe: Service and Repair Pipe-Exhaust Removal 6.7L DIESEL 1. Raise and support the vehicle on a hoist. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust pipe-to-DOC/DPF flange nuts. 4. 4X4 Vehicles - Remove transfer case skid plate. 5. 4X4 Vehicles - Remove transmission crossmember. 6. Remove the exhaust pipe-to-turbocharger clamp and discard. 7. Remove the transmission mounted exhaust pipe support. 8. Separate the exhaust pipe and extension pipe. 9. Remove exhaust pipe. Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Installation 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3428 1. Using a new flange gasket, position exhaust pipe on DOC/DPF flange and turbocharger flange. 2. Install flange nuts. Tighten nuts to 24 Nm (18 ft. lbs.) 3. Install a new exhaust pipe-to-turbocharger clamp. Do not tighten clamp at this time. 4. Install transmission mounted exhaust pipe support. Tighten bolts to 43 Nm (32 ft. lbs.). 5. 4X4 Vehicles - Install transmission crossmember. 6. 4X4 Vehicles - Install transfer case skid plate. 7. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 8. Tighten turbocharger clamp nut to 11 Nm (97 in. lbs.). 9. Lower the vehicle. 10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3429 Exhaust Pipe: Service and Repair Tailpipe Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 4. Disconnect the exhaust tailpipe support hanger isolators. 5. Remove the muffler-to-tailpipe clamps. 6. Remove the tailpipe from the vehicle. Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Installation DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3430 1. Install the tailpipe into the muffler. 2. Install the tailpipe hanger rods into the isolators 3. Install the exhaust clamp, align the exhaust system, and tighten the clamp 48 Nm (35 ft. lbs.) torque. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Lower the vehicle. 6. Connect the battery negative cables. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3435 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3436 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3437 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3438 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3439 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3440 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3443 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3444 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3445 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3446 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3447 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3448 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3454 3. Slide the shield out around the exhaust system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3455 Heat Shield: Service and Repair Installation INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. 2. Tighten the nuts and bolts 11 Nm (100 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3456 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Remove the muffler to tail pipe and extension pipe clamps. 4. Disconnect the muffler from the hanger isolators. 5. Disconnect the muffler from the tailpipe. 6. Disconnect the muffler from the extension pipe and remove from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 3461 Muffler: Service and Repair Installation DIESEL 1. Install the muffler hanger rods into the isolators. 2. Install the muffler into the extension pipe. 3. Install the muffler into the tail pipe. 4. Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 54 Nm (40 ft. lbs.) torque. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Lower the vehicle. 7. Connect the battery negative cables. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3467 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3468 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3469 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3470 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3471 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3472 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3475 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3476 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3477 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3478 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3479 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3480 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3485 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3486 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3487 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3488 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3489 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3490 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3491 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3492 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3495 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3496 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3497 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3498 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3499 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3500 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3501 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3502 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3505 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3508 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3542 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3543 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3544 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3545 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3546 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3547 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3548 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3554 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3559 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3560 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3561 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3562 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3568 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3573 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3574 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3575 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3576 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3581 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3582 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3583 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3584 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3585 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3586 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3587 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3597 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3602 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3603 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3604 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3605 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3615 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3616 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3617 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3618 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3619 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3620 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3621 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3628 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3629 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3630 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3631 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3632 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3633 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3634 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3635 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3636 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3637 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3638 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3639 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3640 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3641 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3642 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3643 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3644 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3645 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3646 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3647 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3648 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3649 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3650 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3651 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3652 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3653 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3654 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3655 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3656 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3657 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3658 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3659 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3660 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3661 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3667 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3668 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3669 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3670 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3671 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3672 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3673 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3700 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3701 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3702 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3703 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3704 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3705 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3706 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3707 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3708 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3709 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3710 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3711 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3712 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3713 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3714 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3719 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3720 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3721 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 3724 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 3725 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 3726 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, 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. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 3727 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 3728 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3731 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3732 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3736 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3737 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3738 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3739 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3740 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3748 8w-30-17 Connector C1 pin 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3770 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 3774 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 3775 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 3776 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 3777 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 3780 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3784 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3785 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3786 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3787 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3788 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3794 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3795 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3796 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3799 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3802 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3806 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3807 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3808 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3809 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3812 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 3818 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3822 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3823 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3824 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3825 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3826 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 3829 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 3832 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3836 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3837 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3838 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3839 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3840 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3841 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3842 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3843 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3844 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3845 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3846 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3847 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3848 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 3851 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3854 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 3859 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 3862 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3866 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3867 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3868 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3869 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3870 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3871 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3872 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3873 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3874 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3875 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3876 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3877 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3878 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3879 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3880 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3881 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3882 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3883 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3884 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3885 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3886 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3887 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3888 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3889 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3890 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3891 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3892 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3893 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3894 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3895 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3896 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3897 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3898 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3901 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3904 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 3908 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 3909 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 3910 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 3911 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 3914 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3919 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3920 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3921 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3922 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3923 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3924 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3925 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3926 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3929 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3930 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3931 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3932 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3933 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3934 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3935 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3936 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3939 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3942 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3947 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3948 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3949 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3950 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3951 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3952 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3955 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3956 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3957 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3958 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3959 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3960 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 3966 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 3970 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 3971 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 3972 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3977 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3978 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3979 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3980 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3981 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3982 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3983 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3984 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3985 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3986 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3987 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3988 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3989 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3990 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3993 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3994 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3995 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3996 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3997 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3998 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 3999 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4000 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4001 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4002 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4003 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4004 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4005 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4006 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4007 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4008 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 4011 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4014 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4015 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4016 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4017 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 4022 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4027 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4028 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4029 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4030 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4031 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4032 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4033 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4034 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4035 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4036 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4037 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4040 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4041 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4042 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4043 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4044 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4045 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4046 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4047 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4048 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4049 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4050 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4051 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4052 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 4055 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4058 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4059 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4060 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4091 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4092 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4093 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4094 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4095 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4096 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4097 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4103 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4104 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4105 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4115 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4116 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4117 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4122 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4123 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4124 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4125 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4126 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4127 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4128 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4138 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4139 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4140 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4150 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4151 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4152 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4153 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4154 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4155 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4156 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4159 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4160 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4161 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4162 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4163 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4164 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4165 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4166 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4167 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4168 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4169 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4170 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4171 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4172 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4173 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4174 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4175 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4176 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4177 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4178 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4179 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4180 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4181 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4182 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4183 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4184 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4185 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4186 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4187 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4188 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4191 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4192 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4193 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4194 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4195 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4196 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4197 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4198 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4199 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4200 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4201 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4202 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4203 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4204 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4205 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4206 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4207 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4208 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4209 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4210 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4211 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4212 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4213 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4214 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4215 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4216 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4217 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4218 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4219 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4220 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4221 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4224 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4225 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4228 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4229 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4230 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 4235 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4240 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4245 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4246 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4247 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4248 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4249 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4250 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4251 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4252 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4253 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4254 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4255 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4258 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4259 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4260 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4261 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4262 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4263 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4264 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4265 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4266 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4267 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4268 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4271 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4272 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4273 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4274 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4275 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4278 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4279 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4280 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4281 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4282 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4286 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4287 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4288 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4316 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4317 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4318 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4319 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4320 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4321 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4322 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4323 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4326 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4327 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4328 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4329 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4330 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4331 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4332 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4333 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4336 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4339 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4343 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4344 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4345 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4346 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 4349 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 4355 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4358 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4359 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4360 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4361 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4362 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 4368 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4373 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4378 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4379 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4380 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4383 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4386 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4390 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4391 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4392 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4393 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4396 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4401 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4402 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4403 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4404 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4405 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4406 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4407 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4410 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4411 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4415 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4416 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4417 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 4422 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4423 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4426 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4427 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4428 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4432 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4433 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4434 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4439 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4440 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4441 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4442 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4443 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4444 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4445 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4446 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4447 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4448 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4449 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4450 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4451 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4454 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4457 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4461 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4462 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4463 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4464 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4465 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4466 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4467 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4468 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4469 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4470 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4471 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4472 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4473 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4474 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4475 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4476 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4477 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4478 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4479 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4480 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4481 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4482 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4483 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4484 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4485 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4486 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4487 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4488 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4489 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4490 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4491 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4492 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4493 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4496 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4499 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 4505 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 4510 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4517 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4518 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4519 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 4528 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 4529 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4534 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4535 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 4538 Fuel Filter: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4541 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4542 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4543 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4544 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4545 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4555 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION 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). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, 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 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 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 4559 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, 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. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4564 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4565 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4566 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4569 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4572 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4576 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4577 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4578 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4579 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4582 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4587 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4588 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4589 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4590 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4591 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4592 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4593 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4594 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4595 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4596 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4597 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4598 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4599 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4600 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4603 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4604 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4605 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4606 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4607 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4608 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4609 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4610 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4611 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4612 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4613 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4614 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4615 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4616 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4617 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4618 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 4621 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4624 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4625 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4626 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4627 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 4633 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4637 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4638 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4639 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4640 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4641 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 4644 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 4647 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4673 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4674 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4675 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4676 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4677 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4678 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4679 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4680 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4681 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4682 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4683 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4684 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4685 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4688 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4691 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4696 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4697 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4698 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4699 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4700 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4701 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4702 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4703 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4706 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4707 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4708 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4709 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4710 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4711 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4712 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4713 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4716 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4719 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4723 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4724 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4725 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4726 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 4729 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 4734 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 4737 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4741 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4742 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4743 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4744 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4745 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4746 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4747 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4748 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4749 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4750 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4751 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4752 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4753 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4754 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4755 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4756 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4757 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4758 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4759 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4760 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4761 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4762 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4763 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4764 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4765 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4766 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4767 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4768 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4769 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4770 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4771 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4772 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4773 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4776 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4779 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector Data Link Connector: Locations Data Link Connector Component ID: 79 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 18BK/LG 5 GROUND Z111 18BK/WT 6 DIAGNOSTIC CAN C (+) D52 20WT/LB 7 SCI TRANSMIT (ECM) D21 18WT/BR 7 SCI TRANSMIT (PCM) D21 18WT/BR 8-9 SCI RECEIVE (TCM) D16 18WT/OR 10 - 11 - 12 SCI RECEIVE (ECM) D20 20WT/LG 12 SCI RECEIVE (PCM) D20 20WT/LG 13 - 14 DIAGNOSTIC CAN C (-) D51 20WT/BR 15 SCI TRANSMIT (TCM) D15 18WT/DG 16 FUSED B(+) A114 18GY/RD Component Location - 49 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4784 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4785 Data Link Connector: Locations Port-Diagnostic Component ID: 232 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A DIAGNOSTIC PORT LOW DATA LINK D132 18WT B DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR C-Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4786 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Data Link Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Data Link Connector: Connector Views Data Link Connector Component ID: 79 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 18BK/LG 5 GROUND Z111 18BK/WT 6 DIAGNOSTIC CAN C (+) D52 20WT/LB 7 SCI TRANSMIT (ECM) D21 18WT/BR 7 SCI TRANSMIT (PCM) D21 18WT/BR 8-9 SCI RECEIVE (TCM) D16 18WT/OR 10 - 11 - 12 SCI RECEIVE (ECM) D20 20WT/LG 12 SCI RECEIVE (PCM) D20 20WT/LG 13 - 14 DIAGNOSTIC CAN C (-) D51 20WT/BR 15 SCI TRANSMIT (TCM) D15 18WT/DG 16 FUSED B(+) A114 18GY/RD Component Location - 49 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Port-Diagnostic Component ID: 232 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A DIAGNOSTIC PORT LOW DATA LINK D132 18WT B DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR C-Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description Data Link Connector: Description and Operation Description DESCRIPTION The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description > Page 4812 Data Link Connector: Description and Operation Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description Electronic Throttle Control Indicator: Description and Operation Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description > Page 4817 Electronic Throttle Control Indicator: Description and Operation Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-ON message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-OFF message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the PCM sends a lamp-ON message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the EMIC and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the EMIC, the CAN data bus or the electronic communication related to ETC indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4826 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4827 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4828 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4829 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4830 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4831 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4832 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 4838 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4843 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4844 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4845 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4846 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 4852 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4857 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4858 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4859 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4860 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4865 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4866 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4867 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4868 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4869 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4870 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4871 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 4881 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4886 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4887 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4888 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4889 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4899 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4900 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4901 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4902 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4903 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4904 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4905 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4912 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4913 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4914 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4915 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4916 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4917 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4918 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4919 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4920 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4921 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4922 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4923 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4924 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4925 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4926 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4927 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4928 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4929 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4930 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4931 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4932 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4933 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4934 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4935 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4936 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4937 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4938 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4939 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4940 56 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4941 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4942 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4943 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4944 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4945 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 56 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5003 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5004 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5005 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5008 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5009 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5010 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, 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. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5011 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5012 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5015 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5016 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5021 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5022 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5023 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5024 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5025 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5026 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5029 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5030 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5031 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5032 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5033 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5034 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 5040 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5044 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5045 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5046 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-02 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 8w-18-03 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 8w-18-04 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 8w-18-05 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 8w-18-06 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 5078 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5082 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5083 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5084 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5085 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5086 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 5091 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5096 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5097 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5098 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5099 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5100 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5101 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5102 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5103 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5104 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5105 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5106 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5109 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5110 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5111 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5112 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5113 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5114 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5115 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5116 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5117 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5118 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5119 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5120 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5121 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 5124 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5127 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5128 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5129 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5160 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5161 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5162 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5163 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5164 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5165 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5166 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5172 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5173 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5174 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5184 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5185 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5186 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5191 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5192 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5193 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5194 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5195 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5196 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5197 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5207 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5208 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5209 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5219 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5220 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5221 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5222 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5223 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5224 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5225 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5228 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5229 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5230 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5231 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5232 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5233 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5234 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5235 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5236 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5237 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5238 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5239 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5240 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5241 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5242 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5243 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5244 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5245 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5246 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5247 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5248 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5249 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5250 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5251 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5252 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5253 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5254 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5255 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5256 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5257 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5260 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5261 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5262 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5263 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5264 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5265 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5266 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5267 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5268 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5269 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5270 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5271 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5272 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5273 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5274 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5275 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5276 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5277 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5278 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5279 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5280 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5281 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5282 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5283 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5284 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5285 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5286 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5287 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5288 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5289 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5290 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5293 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5294 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5297 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5298 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5299 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 5307 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 5312 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5344 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5345 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5346 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5347 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5348 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5349 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5350 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5356 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5361 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5362 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5363 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5364 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5370 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5375 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5376 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5377 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5378 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5383 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5384 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5385 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5386 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5387 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5388 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5389 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5399 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5404 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5405 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5406 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5407 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5417 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5418 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5419 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5420 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5421 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5422 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5423 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5430 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5431 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5432 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5433 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5434 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5435 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5436 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5437 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5438 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5439 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5440 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5441 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5442 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5443 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5444 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5445 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5446 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5447 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5448 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5449 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5450 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5451 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5452 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5453 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5454 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5455 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5456 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5457 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5458 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5459 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5460 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5461 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5462 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5463 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5521 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5522 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5523 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5526 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5527 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5528 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, 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. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5529 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5530 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5533 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5534 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5538 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5539 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5540 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5541 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5542 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5550 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5551 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5552 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 5555 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 5558 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5562 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5563 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5564 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5565 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 5568 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 5574 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5578 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5579 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5580 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5581 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5582 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 5585 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 5588 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5592 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5593 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5594 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5595 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5596 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5597 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5598 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5599 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5600 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5601 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5602 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5603 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5604 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 5607 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 5610 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 5615 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 5618 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5622 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5623 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5624 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5625 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5626 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5627 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5628 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5629 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5630 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5631 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5632 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5633 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5634 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5635 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5636 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5637 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5638 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5639 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5640 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5641 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5642 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5643 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5644 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5645 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5646 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5647 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5648 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5649 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5650 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5651 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5652 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5653 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5654 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 5657 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 5660 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5664 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5665 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5666 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5667 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 5670 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5675 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5676 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5677 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5678 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5679 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5680 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5681 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5682 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5685 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5686 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5687 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5688 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5689 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5690 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5691 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5692 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 5695 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 5698 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5703 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5704 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5705 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5706 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5707 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5708 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5711 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5712 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5713 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5714 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5715 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5716 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 5722 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5726 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5727 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5728 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5733 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5734 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5735 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5736 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5737 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5738 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5739 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5740 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5741 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5742 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5743 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5744 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5745 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5746 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5749 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5750 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5751 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5752 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5753 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5754 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5755 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5756 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5757 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5758 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5759 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5760 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5761 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5762 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5763 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5764 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 5767 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5770 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5771 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5772 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5773 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 5778 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5783 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5784 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5785 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5786 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5787 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5788 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5789 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5790 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5791 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5792 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5793 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5796 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5797 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5798 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5799 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5800 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5801 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5802 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5803 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5804 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5805 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5806 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5807 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5808 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 5811 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5814 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5815 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5816 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5847 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5848 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5849 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5850 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5851 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5852 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5853 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5859 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5860 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5861 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5871 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5872 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5873 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5878 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5879 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5880 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5881 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5882 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5883 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5884 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5894 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5895 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5896 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5906 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5907 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5908 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5909 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5910 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5911 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5912 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5915 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5916 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5917 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5918 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5919 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5920 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5921 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5922 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5923 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5924 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5925 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5926 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5927 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5928 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5929 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5930 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5931 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5932 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5933 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5934 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5935 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5936 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5937 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5938 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5939 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5940 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5941 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5942 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5943 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5944 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5947 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5948 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5949 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5950 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5951 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5952 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5953 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5954 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5955 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5956 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5957 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5958 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5959 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5960 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5961 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5962 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5963 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5964 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5965 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5966 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5967 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5968 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5969 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5970 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5971 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5972 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5973 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5974 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5975 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5976 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5977 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 5980 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 5981 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5984 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5985 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5986 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 5991 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 5996 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6001 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6002 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6003 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6004 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6005 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6006 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6007 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6008 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6009 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6010 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6011 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6014 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6015 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6016 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6017 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6018 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6019 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6020 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6021 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6022 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6023 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6024 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6027 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6028 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6029 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6030 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 6031 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6034 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6035 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6036 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6037 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6038 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6042 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6043 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6044 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6071 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6072 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6073 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6074 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6075 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6076 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6077 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6078 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6079 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6080 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6081 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6084 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6085 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6086 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6087 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6088 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6089 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6090 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6091 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6092 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6093 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6094 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6097 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6098 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6099 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6100 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 6101 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6104 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6105 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6106 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6107 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6108 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6112 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6113 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6114 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6143 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6144 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6145 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6146 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6147 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6148 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6149 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6150 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6153 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6154 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6155 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6156 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6157 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6158 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6159 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6160 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 6163 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 6166 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6173 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6182 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6183 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6189 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6190 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The diesel oxidation catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC/Diesel Particulate Filter (DPF) assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. DIESEL PARTICULATE FILTER The diesel particulate filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 6193 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 6194 Diesel Particle Filter (DPF): Testing and Inspection DIAGNOSIS AND TESTING - DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to - ENGINE Testing. See: Engine, Cooling and Exhaust/Engine/Testing and Inspection/Component Tests and General Diagnostics Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB-CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate. 7. 4X4 Vehicles - Remove transmission crossmember. 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6197 Diesel Particle Filter (DPF): Service and Repair Removal - P/U 6.7L DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Loosen and remove DPF differential pressure tubes (4 and 6). 4. Disconnect and remove temperature sensor (2). 5. 4X4 Vehicles - Remove transfer case skid plate. 6. 4X4 Vehicles - Remove transmission crossmember. 7. Remove DPF to muffler clamp (5). Discard clamp. 8. Move muffler and tail pipe assembly toward rear of vehicle. 9. Remove DPF to catalytic converter flange nuts. 10. Remove DPF. Discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6198 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB-CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten torque clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember. 11. 4X4 Vehicles - Install transfer case skid plate. 12. Connect electrical connectors. 13. Connect negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6199 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U 1. Position new exhaust flange gaskets on catalytic converter to DPF flange. 2. Install flange bolts. Hand tighten only. 3. Install muffler and tailpipe assembly 4. Install new band clamp. Hand tighten only. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Tighten flange nuts to 54 Nm (40 ft. lbs) 7. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 8. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 9. Install front and rear (6 and 4) exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 10. Install flexible exhaust differential pressure sensor tubing. 11. 4X4 Vehicles - Install transmission crossmember. 12. 4X4 Vehicles - Install transfer case skid plate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Component ID: 441 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE SOL SIGNAL K70 20DB/BR Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6204 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6205 Canister Purge Solenoid: Diagrams Component ID: 441 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE SOL SIGNAL K70 20DB/BR Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6206 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Leak Detector: Locations Component ID: 464 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 GROUND Z910 20BK 2 ESM SIGNAL K107 20VT/WT Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6210 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6211 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6212 Leak Detector: Diagrams Component ID: 464 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 GROUND Z910 20BK 2 ESM SIGNAL K107 20VT/WT Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6213 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6214 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Recalls for EGR Cooler: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: Recalls Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Cooler: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: All Technical Service Bulletins Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Page 6229 EGR Cooler: Diagrams Component ID: 498 Component : VALVE-EGR COOLER BYPASS Connector: Name : VALVE-EGR COOLER BYPASS Color : # of pins : 4 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 EGR BYPASS STATUS K671 18BR/DB 2 EGR BYPASS VALVE SIGNAL K670 18BR/LB 3 SMART POWER RELAY FEED F348 16PK/OR 4 ACTUATOR GROUND K972 18DB/TN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description EGR Cooler: Description and Operation Description DESCRIPTION The Exhaust Gas Recycling cooler is located above the exhaust manifold on the right side of the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description > Page 6232 EGR Cooler: Description and Operation Operation OPERATION Exhaust gas enter the rear portion of the EGR Cooler from the exhaust manifold. The gas is cooled as it passes through the EGR Cooler and then enters the EGR crossover tube and is routed to the EGR valve. Coolant enters the rear of the EGR Cooler and flow the same direction as the exhaust gases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures EGR Cooler: Procedures CLEANING 1. Remove EGR Cooler. 2. Spray the internal cavity of EGR Cooler with hot tap water for 10 minutes. 3. Plug EGR Cooler outlet (1) with a locally obtained rubber expansion plug to make a watertight seal. 4. Following instruction on the container, mix MOPAR(R) EGR System Cleaner and hot tap water with a ratio of one part EGR Cleaner, four parts water. 5. Position EGR Cooler with the outlet (1) facing up. Fill EGR Cooler with hot tap water and MOPAR(R) EGR System Cleaner until cooler is completely full. Soak for one hour. 6. Remove plug from EGR Cooler outlet (1). Drain cleaning solution from cooler. Discard according to local governmental regulations. 7. Rinse cooler using hot tap water until all cleaning solution has been rinsed clean. Dry completely. 8. Install EGR Cooler. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6235 EGR Cooler: Removal and Replacement Removal REMOVAL EGR COOLER - 6.7L DIESEL - P/U WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Remove engine cover. 2. Drain cooling system below level of EGR cooler. 3. Disconnect EGR bypass control electrical connector (1), (if equipped). 4. Remove EGR bypass control assembly (2) and position aside, (if equipped). EGR COOLER - 6.7L DIESEL - CAB-CHASSIS 5. Remove EGR crossover tube clamp (4) and crossover tube (5). 6. Remove EGR Transfer Connection Tube from casting, (if equipped). 7. Using Tool 6094, remove forward coolant tube (6) from EGR cooler (2). 8. Using Tool 6094, remove breather tube (7). 9. Using Tool 6094, remove rear coolant tube (8) from EGR cooler (2). 10. Remove EGR Transfer Connection Tube from casting, (if equipped). 11. Remove EGR cooler flange nuts (1). 12. Remove EGR cooler mount bolts. 13. Remove EGR cooler. Discard flange gasket. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6236 INSTALLATION EGR COOLER - 6.7L DIESEL WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Using a new gasket, position EGR cooler (2) on flange. 2. Install flange nuts (1). Tighten to 10 Nm (89 in. lbs.). 3. Install EGR cooler mounting bolts. Tighten to 10 Nm (89 in. lbs). 4. Install EGR crossover tube (5) and crossover tube clamp (4). Tighten clamp nut to 10 Nm (89 in. lbs.). 5. Install EGR Transfer Connection Tube into casting, (if equipped). Tighten clamp nut to 10 Nm (89 in. lbs.). CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver. 6. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube. 7. Using a suitable screwdriver (3), release constant tension clamp (1). 8. Position locking constant tension clamp on rear coolant tube and install tube. 9. Using a suitable screwdriver, release constant tension clamp 10. Position locking constant tension clamp on breather tube and install tube. 11. Using a suitable screwdriver, release constant tension clamp. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6237 EGR COOLER - 6.7L DIESEL - P/U 12. Install EGR Control Assembly, if equipped. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 13. Install EGR Control Assembly electrical connector, (if equipped). 14. Fill coolant system. 15. Install engine cover. 16. Connect negative battery cable(s). 17. Start engine and check for coolant or exhaust leaks. Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Cooler Bypass Valve Assembly (1) is mounted between the EGR crossover tube and the EGR cooler. Two mechanical cables (3) join the units together. An electrical drive servo (4) moves the cables (3) to operate a butterfly plate (2) within a cast manifold. Parts 1, 2, 3 and 4 are serviced as one entire assembly. Do not attempt to disassemble unit. 1. Disconnect and isolate both negative battery cables at both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6238 2. Remove four bolts (2) and remove EGR tube cover (1). 3. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 4. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 5. Remove EGR Crossover Tube (4). 6. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6239 7. Remove nuts (7) and remove upper heat shield (6). 8. Remove bolts (10), nut (8) and remove lower heat shield (9). 9. Remove bolts (5) and (14). 10. Separate casting (4) from casting (15) and discard gasket (3). 11. Disconnect electrical connector (1). 12. Remove bracket bolts (2) at outside of mounting bracket. 13. Remove bracket bolts at inside of mounting bracket. 14. Remove EGR cooler bypass valve assembly from engine. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6240 1. Clean gasket mating surfaces on castings (4) and (15). 2. Position EGR cooler bypass valve assembly to engine. 3. Position new gasket (3) between castings (4) and (15). 4. Install bolts (5) and (14). Do not tighten these bolts at this time. 5. Install bracket bolts (2) at outside of mounting bracket. Do not tighten these bolts at this time. 6. Install bracket bolts at inside of mounting bracket. Do not tighten these bolts at this time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6241 7. Tighten bolts (5) and (14) to 24 Nm (18 ft. lbs.) torque. 8. Tighten bracket bolts (2) at outside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 9. Tighten bracket bolts at inside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 10. Connect electrical connector (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6242 11. Clean each end of EGR crossover tube and its connection points of any old gasket material 12. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 13. Position EGR crossover tube (4) to engine. 14. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 15. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 16. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). 17. Install upper heat shield (6) and nuts (7). Tighten nuts to 24 Nm (18 ft. lbs.) torque. 18. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6243 19. Install EGR tube cover (1) and four bolts (2). 20. Connect and both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 6249 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6252 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6253 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6254 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6255 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6256 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal EGR Tube: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). 3. Remove heat shield (2) over EGR valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6261 4. Disconnect electrical connector (4) at EGR Temperature Sensor. 5. Loosen and remove two clamps (1) and (3) at ends of EGR Crossover Tube. 6. Remove "P" clamp mounting bolt (5) at center of EGR Crossover Tube. 7. Remove EGR Crossover Tube (2). 8. Remove and discard gaskets (doughnuts) at each end of tube. Removal-Pick Up Models REMOVAL-PICK UP MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6262 3. Remove heat shield (2) over EGR valve (1). 4. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 5. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 6. Remove EGR Crossover Tube (4). 7. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6263 EGR Tube: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Clean each end of EGR crossover tube, and its connection points of any old gasket material 2. Install new gaskets (doughnuts) to each end of tube. 3. Position EGR crossover tube (2) to engine. 4. Position "P" clamp (5) at center of EGR crossover tube. Install "P" clamp bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (3) to 10 Nm (7 ft. lbs.). 6. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 7. Connect electrical connector (4) to EGR temperature sensor. 8. Install heat shield (2) over EGR valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6264 9. Install cover (1) and four cover bolts (2). 10. Connect both negative battery cables to both batteries. Installation-Pick Up Models INSTALLATION-PICK UP MODELS 1. Clean each end of EGR crossover tube and its connection points of any old gasket material 2. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 3. Position EGR crossover tube (4) to engine. 4. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 6. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6265 7. Install heat shield (2) over EGR valve (1). 8. Install cover (1) and four cover bolts (2). 9. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve EGR Valve: Locations Assembly-EGR Valve Component ID: 14 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6270 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6271 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6272 Pin Description Circuit 1 EGR SIGNAL K34 20DB/LG 2 5 VOLT SUPPLY F856 20YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GROUND Z335 20BK/WT 5-6 EGR SOL CONTROL K35 20DB/VT Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6273 EGR Valve: Locations Valve-EGR Airflow Control Component ID: 497 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6274 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6275 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve EGR Valve: Diagrams Assembly-EGR Valve Component ID: 14 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6278 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6279 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6280 Pin Description Circuit 1 EGR SIGNAL K34 20DB/LG 2 5 VOLT SUPPLY F856 20YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GROUND Z335 20BK/WT 5-6 EGR SOL CONTROL K35 20DB/VT Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6281 EGR Valve: Diagrams Valve-EGR Airflow Control Component ID: 497 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6282 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6283 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve EGR Valve: Service and Repair EGR Valve Removal-Pick Up Models REMOVAL-PICK UP MODELS 1. Disconnect and isolate both negative battery cables at both batteries. 2. Remove four bolts (2) and remove EGR crossover tube cover (1). 3. Remove EGR valve heat shield (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6286 4. Loosen (only) clamp (6). Remove clamp (1) at end of EGR Crossover Tube. 5. Remove bolt (3) at center of EGR Crossover Tube. 6. Disconnect electrical connector at end of valve assembly. 7. Remove two EGR valve assembly mounting bolts and two nuts (1). 8. Remove EGR valve assembly (2) from intake connector (3) by prying up. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6287 9. Remove crossover tube doughnut gasket (1) and clean EGR valve. Also clean end of EGR tube of any old gasket material. 10. Remove two gaskets on bottom EGR valve (4). Clean bottom of EGR valve and top of its intake connection point of any old gasket material. 11. To prevent contaminants, cover the exposed opening at intake connection. Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS 1. Disconnect and isolate both negative battery cables at both batteries. 2. Remove four bolts (2) and remove EGR crossover tube cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6288 3. Remove EGR valve heat shield (2). 4. Disconnect electrical connector (5) at EGR Actuator. 5. Loosen (only) clamp (1). Remove clamp (3) at end of EGR Crossover Tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6289 6. Loosen (only) bolt at "P" clamp (5) at center of EGR Crossover Tube. 7. Remove two EGR valve assembly mounting bolts and two nuts (1). 8. Remove EGR valve assembly (2) from intake connector (3) by prying up. 9. Remove crossover tube doughnut gasket (1) and clean EGR valve. Also clean end of EGR tube of any old gasket material. 10. Remove two gaskets on bottom EGR valve (4). Clean bottom of EGR valve and top of its intake connection point of any old gasket material. 11. To prevent contaminants, cover the exposed opening at intake connection. Cleaning CLEANING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6290 6.7L EGR VALVE CLEANING PROCEDURE 1. Remove EGR valve assembly from engine. 2. Remove four mounting screws (4) from EGR valve motor (3). 3. Remove valve motor (6) and shim (5) from EGR valve housing (1). Motor (6) and shim (5) must be kept for reassembly. The original EGR valve motor and its shim must be reinstalled onto the original EGR valve housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6291 4. Use two fingers to press down on valve spring retainer (3) to unlock two valve keepers (2). If valve keepers will not release using finger pressure, locate a 5/8 inch deep socket to the spring retainer (3). Gently tap on the socket with a small hammer to release keepers, then use two fingers and press for keeper removal. 5. Remove valve spring retainer (3) and valve spring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6292 6. Lightly press on valve stem (1) about 3/8 inch to force valve faces from valve seats. 7. Using a small nylon scrubbing brush, lightly brush away loose soot from EGR valve housing. 8. The EGR valve shaft stem (3) is comprised of two valve faces (1) on two valve seats. Using the same small nylon scrubbing brush, lightly brush away loose soot from stem (3), valve seat (2) and also from valve seat on EGR valve housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6293 9. Completely submerge valve housing using a mixture of hot tap water and MOPAR(R) EGR System Cleaner (ESC). Mix cleaning solution 1 part ESC and 4 parts water. Allow cleaning solution to soak for 1 hour. 10. Remove assembly from cleaning solution. Completely remove remaining soot from valve stems, both valve seats, and both valve faces using a small nylon scrubbing brush. Dispose of cleaning solution per local governmental regulations. 11. Rinse EGR valve housing in hot tap water until all cleaning solution is rinsed clean. Dry completely. 12. Assemble valve spring (2) and retainer (3) to housing. 13. Position valve keepers (2). Press down on retainer (3) until groves on valve keepers lock into valve stem (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6294 14. Install original shim (5) and original motor (6) to housing. Motor is not indexed. Rotate motor until its electrical connector is pointed towards front of vehicle. Install four mounting screws (7). 15. Install EGR valve assembly to engine. Installation-Pick Up Models INSTALLATION-PICK UP MODELS 1. Install new gasket (1) to end of EGR tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6295 2. Position EGR valve assembly (2) and two new gaskets to intake connection (3). 3. Install two EGR valve mounting bolts (1) and two nuts (1). Tighten four nuts/bolts finger tight only. 4. Install and lightly tighten two clamps (1) and (6) at ends of EGR Crossover Tube. 5. Install bolt (3) finger tight only. 6. Tighten clamp (6) first to 10 Nm. (7 ft. lbs.), then tighten clamp (1) to 10 Nm. (7 ft. lbs.). 7. Tighten tube bolt (3) to 10 Nm (7 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6296 8. Tighten two EGR valve mounting bolts and two nuts (1) to 24 Nm (18 ft. lbs.). Tighten these four nuts/bolts in an alternating, criss-cross fashion. 9. Connect electrical connector to EGR Actuator. 10. Install EGR crossover tube cover (1) and four bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6297 11. Install EGR valve heat shield (2). Tighten bolts/nuts to 10 Nm (7 ft. lbs.). 12. Connect both negative battery cables to both batteries. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Install new gasket (1) to end of EGR tube. 2. Position EGR valve assembly (2) and two new gaskets to intake connection (3). 3. Install two EGR valve mounting bolts (1) and two nuts (1). Tighten four nuts/bolts finger tight only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6298 4. Install and lightly tighten two clamps (1) and (3) at ends of EGR Crossover Tube. 5. Install "P" clamp bolt (5) finger tight only. 6. Tighten clamp (1) first to 10 Nm. (7 ft. lbs.), then tighten clamp (3) to 10 Nm. (7 ft. lbs.). 7. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 8. Tighten two EGR valve mounting bolts and two nuts (1) to 24 Nm (18 ft. lbs.). Tighten these four nuts/bolts in an alternating, criss-cross fashion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6299 9. Connect electrical connector (5) to EGR Actuator. 10. Install EGR crossover tube cover (1) and four bolts (2). 11. Install EGR valve heat shield (2). Tighten bolts/nuts to 10 Nm (7 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6300 12. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6301 EGR Valve: Service and Repair EGR Valve Air Flow Control Removal REMOVAL The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Remove clamp for charge air cooler duct at point (5). Disconnect air cooler duct at this point. 2. Disconnect electrical connector at point (2). This point is located at bottom/inside of air control valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6302 3. Remove four mounting bolts (4) and (6) and remove air flow control valve (5). 4. Remove gasket (3) and discard. Installation INSTALLATION The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Obtain new gasket (3). Before positioning new gasket (3), be sure to clean mating surfaces at top of air flow control valve and bottom of air intake connection (2). 2. Install four mounting bolts (4) and (6). Tighten four bolts to 18 Nm (13 ft. lbs.) (160 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6303 3. Connect electrical connector at point (2). 4. Connect air cooler duct to bottom of air flow control valve. Install and tighten duct clamp. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6308 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation > Page 6313 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Removal Crankcase Filter: Service and Repair Removal REMOVAL 1. Using hose clamp pliers, loosen the breather plumbing from the breather cover connections. 2. Carefully remove the breather hoses (2) from the breather cover assembly (3). 3. Remove the capscrews surrounding the parameter of the breather cover (3). 4. Separate the breather cover (3) assembly from the cylinder head cover (1). FILTER ELEMENT REMOVAL 1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the element straight up from its sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Removal > Page 6316 Crankcase Filter: Service and Repair Installation FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6320 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6321 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6322 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6323 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 6326 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations PCV FILTER The crankcase breather/filter is no longer used with the 3.9L, 5.2L or 5.9L engine. PCV VALVE All 3.9L V-6 and 5.2L/5.9L V-8 gas powered engines are equipped with a closed crankcase ventilation system and a positive crankcase ventilation (PCV) valve. The 8.0L V-10 engine is not equipped with a PCV valve. Refer to Crankcase Ventilation System-8.0L V-10 Engine for information. Fig. 4 Typical PCV Valve/Hose (Non-California Shown) This system consists of a PCV valve mounted on the cylinder head (valve) cover with a hose extending from the valve to the intake manifold. Another hose connects the opposite cylinder head (valve) cover to the air cleaner housing to provide a source of clean air for the system. A separate crankcase breather/filter is not used. Fig. 5 Typical Closed Crankcase Ventilation System The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 6330 pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 6 Engine Off Or Engine Pop-Back - No Vapor Flow When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Fig. 7 High Intake Manifold Vacuum - Minimal Vapor Flow During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Fig. 8 High Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6336 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6337 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6338 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6339 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6340 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6341 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6342 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6343 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6346 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6347 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6348 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6349 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6350 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6351 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6352 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6353 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 6356 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 6359 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6363 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6364 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6365 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6366 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 6369 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 6375 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6378 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6379 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6380 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6381 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6382 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6388 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6393 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6400 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6401 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6402 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6409 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6410 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6411 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 6414 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 6417 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 6423 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 6424 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6428 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6429 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6430 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6431 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 6434 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control Fuel Inlet Metering Valve: Locations Actuator-Fuel Control Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 2 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 2 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6440 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6441 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6442 Fuel Inlet Metering Valve: Locations Actuator - Fuel Control The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6443 Fuel Inlet Metering Valve: Diagrams Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 2 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 2 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6444 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6445 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Valve-Cascade Overflow Fuel Inlet Metering Valve: Description and Operation Valve-Cascade Overflow Description DESCRIPTION NOTE: The cascade overflow valve is not serviced separately. The cascade overflow valve (4) is located on the top/rear side of the fuel injection pump. Operation OPERATION When the fuel control actuator (FCA) is opened, the maximum amount of fuel is being delivered to the fuel injection pump. The cascade valve regulates how much excess fuel is used for lubrication of the injection pump, and is also used to route excess fuel through the drain circuit and back into the fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Valve-Cascade Overflow > Page 6448 Fuel Inlet Metering Valve: Description and Operation Actuator - Fuel Control Description DESCRIPTION The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Operation OPERATION The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through the drain manifold. An audible click from the FCA is normal when operating the key from the ON to the OFF position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal Fuel Inlet Metering Valve: Service and Repair Removal REMOVAL 1. Remove electrical connector (6) from Fuel Control Actuator (FCA). 2. Remove FCA mounting screws (1). 3. Twist and pull FCA to remove from injection pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal > Page 6451 Fuel Inlet Metering Valve: Service and Repair Installation INSTALLATION 1. Lubricate new Fuel Control Actuator (FCA) O-ring with clean oil before installation. 2. Turn FCA in a clockwise direction while pressing it into machined bore on rear of fuel injection pump. Be sure FCA flange is flush with the mounting surface on fuel injection pump. 3. Install FCA mounting screws (1) by hand. 4. Tighten FCA mounting screws (1) to 7 Nm (62 in. lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6456 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6457 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description > Page 6460 Fuel Filter: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6463 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6464 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6465 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6466 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6467 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel Fuel Heater: Locations Heater-Fuel Component ID: 139 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A GROUND Z902 14BK A GROUND Z816 14BK B FUEL HEATER CONTROL OUTPUT A961 14RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 6472 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 6473 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 6474 Fuel Heater: Locations Fuel Heater Element The heater element (2) is located in the fuel filter housing (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6475 Fuel Heater: Diagrams Component ID: 139 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A GROUND Z902 14BK A GROUND Z816 14BK B FUEL HEATER CONTROL OUTPUT A961 14RD Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6476 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6477 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6478 Fuel Heater: Description and Operation OPERATION The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. When the fuel temperature is below 45 ± 8° F (7° C), the temperature sensor allows current to flow to the heater element warming the fuel. When the fuel temperature is above 75 ± 8° F (24° C), the sensor stops current flow to the heater element. Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a solid stated device in the TIPM. The fuel heater element and "solid state device in TIPM" are not computer controlled. The heater element operates on 12 volts, 300 watts at 0° F (-18° C). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6479 Fuel Heater: Testing and Inspection FUEL HEATER The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. NOTE: The fuel heater element, "solid state device in TIPM" is not controlled by the Engine Control Module (ECM). A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel waxing. The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing. The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel temperature. When fuel temperature drops below 45 ° ± 8° F (7° C), the sensor allows current to flow to built-in heater element to warm fuel. When fuel temperature rises above 75° ± 8° F (24° C), the sensor stops current flow to heater element (circuit is open). Voltage to operate fuel heater element is supplied from ignition switch, through "solid state device in TIPM", to fuel temperature sensor and on to fuel heater element. The heater element operates on 12 volts, 300 watts at 0° F (-18° C). As temperature increases, power requirements decrease. A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less than 1 ohm (cold) and up to 1000 ohms warm. TESTING 1. Disconnect electrical connector (1) from heater element. Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient temperature by placing ice packs on thermostat to produce an effective ambient temperature below circuit close temperature. Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms. 2. If resistance is out of range, replace heater element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6480 Fuel Heater: Service and Repair Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). Check condition of fuel heater O-ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 Fuel Injector: Locations Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6485 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6486 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6487 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6488 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6489 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6490 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6491 Fuel Injector: Locations Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6492 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6493 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6494 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6495 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6496 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6497 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6498 Fuel Injector: Locations Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6499 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6500 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6501 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6502 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6503 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6504 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6505 Fuel Injector: Locations Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6506 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6507 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6508 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6509 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6510 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6511 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6512 Fuel Injector: Locations Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6513 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6514 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6515 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6516 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6517 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6518 Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6519 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6520 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6521 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6522 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6523 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6524 Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6525 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6526 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6527 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6528 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6529 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6530 Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6531 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6532 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6533 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6534 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6535 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6536 Injector-Fuel 5 Component ID: 149 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6537 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 5 K638 14BK 2 INJECTOR CONTROL NO. 5 K38 14BK Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6538 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6539 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 5 K38 18BR/OR 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6540 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6541 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6542 Injector-Fuel 6 Component ID: 150 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6543 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 6 K658 14BK 2 INJECTOR CONTROL NO. 6 K58 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6544 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6545 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 6 K58 18BR/VT 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6546 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6547 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6548 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6551 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6552 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6553 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6554 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6555 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6556 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6557 Fuel Injector: Diagrams Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6558 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6559 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6560 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6561 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6562 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6563 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6564 Fuel Injector: Diagrams Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6565 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6566 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6567 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6568 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6569 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6570 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6571 Fuel Injector: Diagrams Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6572 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6573 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6574 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6575 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6576 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6577 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6578 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6579 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6580 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6581 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6582 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6583 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6584 Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6585 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6586 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6587 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6588 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6589 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6590 Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6591 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6592 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6593 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6594 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6595 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6596 Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6597 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6598 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6599 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6600 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6601 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6602 Injector-Fuel 5 Component ID: 149 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6603 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 5 K638 14BK 2 INJECTOR CONTROL NO. 5 K38 14BK Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6604 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6605 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 5 K38 18BR/OR 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6606 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6607 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6608 Injector-Fuel 6 Component ID: 150 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6609 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 6 K658 14BK 2 INJECTOR CONTROL NO. 6 K58 14BK Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6610 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6611 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 6 K58 18BR/VT 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6612 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6613 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6614 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description Fuel Injector: Description and Operation Description DESCRIPTION Six individual, solenoid actuated high-pressure fuel injectors are used (6). The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (13), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line (1). FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 6617 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 6618 Fuel Injector: Description and Operation Operation OPERATION High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail, through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel connector is positioned into the cylinder head and sealed with an O-ring. The connector is retained in the cylinder head by a nut (fitting) that is threaded into the cylinder head. The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and the fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be visible. The result will be a possible fuel injector miss-fire and low power, or a no-start condition. The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. Because of this, it is very important to do a thorough cleaning of any lines before opening up any fuel system component. Always cover or cap any open fuel connections before a fuel system repair is performed. Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel system components during repair. The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gasket). The correct thickness shim must always be re-installed after removing an injector. Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 6619 Fuel Injector: Testing and Inspection *INJECTOR RETURN FLOW TEST 1. ENGINE RUNS NOTE: Review Warranty bulletin D-05-24. NOTE: Battery charger may be utilized if cranking speed is below 170 RPM's. Does the engine run? Yes - Go To 2 No - Go To 3 2. * INJECTOR RETURN FLOW TEST @ 1200 RPM AND 1400 BAR RAIL PRESSURE 1. Operate the engine until the coolant temperature is above 180° F. 2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. 3. Install fuel system test fitting 9012 in place of the banjo connector. 4. Remove the vehicle fuel return line from the engine fuel drain tube. 5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank. 6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated cylinder. 7. Start engine and allow to idle for 30 sec. This step allows the flows to stabilize. Gather appropriate measuring device to measure collected return fuel. 8. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure override test. Select Start, then press Next. 9. Press the Run button on the screen. As you press the Run button to start the overpressure test, please move the injector return hose from the bucket and insert into the appropriate measuring device. The engine speed will elevate rapidly to 1200 rpm and the rail pressure will increase to 20000 psi (1400 bar). 10. While the test is running, please record the FCA duty cycle % and actual rail pressure record the readings on the Cummins Diesel Diagnostic Worksheet located under e-files, service, Star center in dealerconnect. 11. Measure and Record the amount of fuel collected. 12. If the flow is less than 160 ml/30 secs, the test has successfully passed, and the condition has been fixed 13. If the flow is greater than 250 ml/30 seconds, refer to step 20. 14. If the flow is greater than 160 ml/30 secs after step 11, shut off the engine and remove all 6 high pressure fuel lines. Re-torque the high-pressure connector nut. Inspect for damage, repair/replace as necessary. Reinstall high pressure fuel lines. 15. Start the engine and perform steps 7 through 10. 16. Measure the amount of fuel in the graduated cylinder. 17. If the amount of fuel is greater than 160 ml/30 sec, shut off the engine and remove the #1 high pressure fuel line. Cap the #1 fuel port using tool 9011 on the fuel rail and repeat steps 7 through 10. 18. Measure the amount of fuel in the graduated cylinder. If the amount is less than 160 ml.30 sec, remove and replace the #1 injector and #1 High pressure connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 6620 19. If the amount of fuel is not less than 160-ml/30 secs, repeat steps 17-18 for cylinders 2-6. 20. If the amount of fuel is greater than 250 ml/30 secs it is recommended that all 6 injectors be replaced. 21. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. SPECIFICATION: Less than 160 ml/ 30 seconds total fuel returns flow Repair - Test Complete. 3. * INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM WHEN THE VEHICLE WILL NOT START 1. Install 9012 fitting in standard location on back of fuel filter head to measure pump and injector return flows. 2. Install hoses to the test fitting and the injector return line and route them to a bucket or other container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing. 3. Unplug the injector harnesses at the valve cover, Unplug the connector to the FCA. 4. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished. 5. Let all the fuel drain out of each line before continuing. 6. Place the injector return hose into an appropriate measuring device. 7. Crank the engine for 10 seconds. Go from Keyoff to Crank back to Keyoff. Do not leave the ignition on between tests. 8. Let all of the fuel drain out of the injector hose. 9. Record the amount of injector return for a 10 sec crank. 10. Flow should be less than 40 ml for 10 seconds of cranking 11. If the flow is greater than 40 ml after step 10, remove the #1 fuel injector supply line. Re-torque the high-pressure connector nut. Cap the #1 fuel port using tool 9011 on the fuel rail. 12. Crank the engine and perform steps 7 through 9. 13. Measure the amount of fuel in the graduated cylinder. 14. If the amount of fuel is less than 40 ml, remove the #1 high pressure connector and the #1 fuel injector. Inspect for damage, repair/replace as necessary. 15. If the amount of fuel is not less than 40 ml, repeat steps 12-14 for cylinders 2-6. 16. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. Repair - Note: DTC's will be set by this process. Remember to go in and clear all DTC's from all modules. Test complete. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal Fuel Injector: Service and Repair Removal REMOVAL FUEL INJECTOR ID CORRECTION CODES: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. CAUTION: Refer to Cleaning Fuel System Parts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6623 Six individual, solenoid actuated high-pressure fuel injectors (7) are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Remove vanity cover. 3. Remove breather assembly and tubes. 4. Remove valve cover. 5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6624 6. An integrated fuel injector wire harness / valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3). 7. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector. 8. A connector retainer (nut) is used on each connector tube (12). Remove this nut(s) by unthreading from cylinder head. These nuts (12) hold the fuel injector retainers (13) to the fuel injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6625 9. Using special high-pressure connector removal tool #9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head. 10. Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed. 11. Remove necessary exhaust rocker arm assembly(s). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6626 12. USING TOOL #9010: a. Special Tool #9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur. b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges. c. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half. d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action. e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head. f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together. g. Be sure handle pivot nut is loose. h. Depress handle downward to remove fuel injector straight up from cylinder head bore. 13. Remove and discard injector sealing washer (2). This washer (2) should be located on tip of injector, or may have remained in the injector bore. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6627 14. Measure sealing gasket (washer) (1). NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6628 Fuel Injector: Service and Repair Installation INSTALLATION 1. Inspect fuel injector : a. Look for burrs on injector inlet. b. Check nozzle holes for hole erosion or plugging. c. Inspect end of nozzle for burrs or rough machine marks. d. Look for cracks at nozzle end. e. If any of these conditions occur, replace injector. 2. Record six-digit alphanumeric correction code located on the side of injector. 3. Inspect high-pressure fuel injector connector for : a. Damaged tip. b. Loose of missing alignment pin. c. Cut or missing O-ring. 4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air. 5. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (0.060 inch) 6. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation. 7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6629 8. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector. 9. Tightening Sequence: a. Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 Nm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered. b. After tightening, relieve bolt torque, but leave both bolts threaded in place. c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 Nm (11 ft. lbs.) torque. d. Alternately tighten injector holdown bolts to 8 Nm (71 in. lbs.) torque. e. Do a final tightening of the high-pressure connector and retaining nut (12). Tighten to 50 Nm (37 ft. lbs.) torque. 10. Install integrated gasket 11. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur. 12. Install exhaust rocker arm assembly. 13. Set exhaust valve lash. 14. Install fuel connector tube nut at cylinder head and tighten to 50 Nm (37 ft. lbs.). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. 15. Install valve cover. 16. Install breather assembly. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 6630 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. 1. Connect negative battery cables to both batteries. 2. Programming Fuel Injector Correction Code: - Turn ignition switch "ON". - Using a diagnostic scan tool, select ECU View> PCM > MISCELLANEOUS FUNCTIONS. - Select Injector Quantity Adjustments and click Start. - Choose appropriate cylinder number and click next. - Click on Show Keyboard. NOTE: A fault code will be set if incorrect serialization codes have been inputted. - Input six-digit Injector Correction Code and click enter. - Review code as it was typed, then click Next if correct, or edit if necessary. - Repeat the preceding steps for other cylinders if necessary. - Once all fuel injector correction codes are entered, cycle the ignition to complete. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations The fuel pressure limiting valve (1) is screwed into the front of the fuel rail (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 6634 Fuel Pressure Regulator: Description and Operation OPERATION Fuel pressure at the fuel rail is monitored by the fuel rail pressure sensor. If fuel pressure becomes excessive, the pressure limiting valve opens and vents excess fuel pressure vents through the fuel pressure limiting valve drain port. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal Fuel Pressure Regulator: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. The fuel pressure limiting valve (1) is screwed into the front of the fuel rail (2). The fuel pressure limiting valve drain port is located on the side of the fuel rail next to the limiting valve. The drain port is not serviceable. 1. Thoroughly clean area at pressure limiting valve (1). 2. To gain access to the limiting valve, the intake connection/EGR valve assembly must be removed. Loosen clamp (5) securing EGR crossover tube (6) to EGR valve. Also loosen opposite end of EGR crossover tube. Remove clamp from intake connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 6637 3. Remove six bolts (1) securing intake connection (2). Lift the entire EGR valve/intake connection up and to the side to gain access to fuel pressure limiting valve. 4. Discard gasket (3). 5. Remove pressure limiting valve from fuel rail. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 6638 Fuel Pressure Regulator: Service and Repair Installation INSTALLATION 1. Be sure both end of manifold and limiting valve mounting area are clean. 2. Lubricate O-ring on limiting valve with fresh diesel oil. Also lubricate limiting valve threads with fresh diesel oil. 3. Install valve (1) and torque to 100 Nm (74 ft. lbs.). To prevent leaks, valve MUST be tightened to prescribed torque. 4. Install new intake connection gasket (3). 5. Position EGR valve/intake connection and install six bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 6. Install new EGR crossover tube gasket. Tighten crossover tube clamps to 10 Nm (88 in. lbs.). 7. Using a diagnostic scan tool, reset vale life by using the "Reset Two-Stage Dump Valve Accumulator" function in the PCM portion of the diagnostic tool Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 6639 8. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6644 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6645 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6646 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6647 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6648 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6649 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6650 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6653 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6654 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6661 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6662 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6663 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 6667 8w-30-17 Connector C1 pin 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 6689 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation OPERATION The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel lines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal Fuel Rail: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. 1. Disconnect both negative battery cables at both batteries. Isolate ends of both cables. 2. Disconnect electrical connector at fuel pressure sensor (2). 3. Disconnect electrical connector at MAP sensor (3). 4. Disconnect necessary wiring harness retention clips from intake manifold. 5. Disconnect cables for intake air heater. 6. Remove fuel line (8). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 6695 7. Loosen fittings (9). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 8. Loosen fittings (11) and remove all fuel lines (1). Note and mark position of each fuel line while removing. 9. Remove fuel line connecting injection pump to fuel rail. 10. Remove fuel injection rail mounting bolts (7). 11. Remove rail (6) from top of intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 6696 Fuel Rail: Service and Repair Installation INSTALLATION 1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail. 2. Position fuel rail to top of manifold and install rail mounting bolts (7). Torque bolts to 24 Nm (18 ft. lbs.). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 3. Install all high-pressure lines to rail. Torque fittings to 30 Nm (22 ft. lbs.). 4. Reposition wiring harness to intake elbow and install nut. 5. Install two new sealing washers to fuel limiting valve banjo bolt. Torque to 24 Nm (18 ft. lbs.). 6. Connect electrical connector to fuel pressure sensor (2). 7. Connect electrical connector to MAP sensor (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 6697 8. Install air intake heater cables. 9. Connect battery cables to both batteries. 10. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Description Fuel Return Line: Description and Operation Description DESCRIPTION Low-Pressure Lines Are: - the fuel supply line from fuel tank to fuel filter housing. - the fuel return line back to fuel tank. - the fuel drain (manifold) line at rear of cylinder head. - the fuel supply line from fuel filter to fuel injection pump. - the fuel injection pump return line. High-Pressure Lines Are: - the fuel line from fuel injection pump to fuel rail. - the six fuel lines from fuel rail up to injector connector tubes WARNING: High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 180,000 kpa (26,107 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Description > Page 6702 Fuel Return Line: Description and Operation Operation OPERATION High-Pressure Lines CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180,000 kPa (26,107 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. WARNING: Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Removal Fuel Return Line: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at both ends. CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting (11), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result. 3. If removing fuel line at # 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to # 6 fuel line connection. 4. If removing fuel line at either #1 or #2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. 5. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine. 6. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Removal > Page 6705 Fuel Return Line: Service and Repair Installation INSTALLATION All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. CAUTION: Anytime a high-pressure line is removed from the engine, its fuel connector nut (12) at the cylinder head must first be retorqued. 1. Tighten nuts (12) at high pressure injector connector nut at the cylinder head. Torque nut to 50 Nm (37 ft. lbs.). 2. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line. 3. Tighten fuel line at cylinder head. Torque nut to 40 Nm (30 ft. lbs.). 4. Tighten fuel line nuts at fuel rail to 40 Nm (30 ft. lbs.). 5. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket (4) upward and tighten two bolts (3) at rear of cylinder head. Tighten to 43 Nm (32 ft. lbs.). 6. If necessary, install EGR valve/air intake manifold assembly. 7. Connect both negative battery cables to both batteries. 8. Prime fuel system. 9. Check lines/fittings for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description Fuel Supply Line: Description and Operation Description DESCRIPTION Low-Pressure Lines Are: - the fuel supply line from fuel tank to fuel filter housing. - the fuel return line back to fuel tank. - the fuel drain (manifold) line at rear of cylinder head. - the fuel supply line from fuel filter to fuel injection pump. - the fuel injection pump return line. High-Pressure Lines Are: - the fuel line from fuel injection pump to fuel rail. - the six fuel lines from fuel rail up to injector connector tubes WARNING: High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 180,000 kpa (26,107 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description > Page 6710 Fuel Supply Line: Description and Operation Operation OPERATION High-Pressure Lines CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180,000 kPa (26,107 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. WARNING: Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal Fuel Supply Line: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at both ends. CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting (11), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result. 3. If removing fuel line at # 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to # 6 fuel line connection. 4. If removing fuel line at either #1 or #2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. 5. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine. 6. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal > Page 6713 Fuel Supply Line: Service and Repair Installation INSTALLATION All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. CAUTION: Anytime a high-pressure line is removed from the engine, its fuel connector nut (12) at the cylinder head must first be retorqued. 1. Tighten nuts (12) at high pressure injector connector nut at the cylinder head. Torque nut to 50 Nm (37 ft. lbs.). 2. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line. 3. Tighten fuel line at cylinder head. Torque nut to 40 Nm (30 ft. lbs.). 4. Tighten fuel line nuts at fuel rail to 40 Nm (30 ft. lbs.). 5. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket (4) upward and tighten two bolts (3) at rear of cylinder head. Tighten to 43 Nm (32 ft. lbs.). 6. If necessary, install EGR valve/air intake manifold assembly. 7. Connect both negative battery cables to both batteries. 8. Prime fuel system. 9. Check lines/fittings for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 6737 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 6740 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Shield > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Shield: > NHTSA07V247000 > Jun > 07 > Recall 07V247000: Fuel Tank Shield Installation Fuel Tank Shield: Recalls Recall 07V247000: Fuel Tank Shield Installation MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2500 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V247000 MFR'S REPORT DATE: June 05, 2007 COMPONENT: Fuel System, Gasoline:Storage POTENTIAL NUMBER OF UNITS AFFECTED: 5062 SUMMARY: Certain pickup trucks equipped with 34 gallon fuel tanks fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 301, "Fuel System Integrity." The fuel tank may become damaged during certain crash conditions, which could allow fuel leakage to occur if the vehicle rolls over. CONSEQUENCE: Fuel leakage, in the presence of an ignition source, could result in a fire. REMEDY: Dealers will install a fuel tank shield onto the front frame cross member. The recall began on June 12, 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall No. G16. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Shield: > NHTSA07V247000 > Jun > 07 > Recall 07V247000: Fuel Tank Shield Installation Fuel Tank Shield: All Technical Service Bulletins Recall 07V247000: Fuel Tank Shield Installation MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2500 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V247000 MFR'S REPORT DATE: June 05, 2007 COMPONENT: Fuel System, Gasoline:Storage POTENTIAL NUMBER OF UNITS AFFECTED: 5062 SUMMARY: Certain pickup trucks equipped with 34 gallon fuel tanks fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 301, "Fuel System Integrity." The fuel tank may become damaged during certain crash conditions, which could allow fuel leakage to occur if the vehicle rolls over. CONSEQUENCE: Fuel leakage, in the presence of an ignition source, could result in a fire. REMEDY: Dealers will install a fuel tank shield onto the front frame cross member. The recall began on June 12, 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall No. G16. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Tank Vent: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6758 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal Fuel Tank Unit: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 6764 Fuel Tank Unit: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Locations Fuel/Water Separator: Locations The fuel filter/water separator assembly is located on left side of engine above the starter motor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description Fuel/Water Separator: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description > Page 6770 Fuel/Water Separator: Description and Operation Operation OPERATION 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 filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal Fuel/Water Separator: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the 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). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6773 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6774 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6775 Fuel/Water Separator: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6776 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6777 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6781 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6782 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6783 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 6788 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 6789 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 6790 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 6791 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 6794 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6798 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6799 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6800 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6801 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6802 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 6807 8w-30-17 Connector C1 pin 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 6829 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 6833 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 6834 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 6835 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 6836 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 6839 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6843 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6844 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6845 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6846 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6847 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6852 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6853 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6854 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 6857 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 6860 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6864 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6865 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6866 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6867 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 6870 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6875 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6876 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 6877 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6878 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6879 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6880 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6881 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6884 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6885 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6889 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6890 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6891 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 6896 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 6897 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6900 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6901 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6902 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 6906 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 6907 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 6908 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations Component ID: 495 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (3.7L) Pin Description Circuit 1 ETC MOTOR (+) K447 20TN/YL 2 5 VOLT SUPPLY F855 20PK/YL 3 TP SENSOR RETURN K922 20BR/DB 4 ETC MOTOR (-) K448 20TN/OR 5 TP NO. 2 SIGNAL K122 20BR/DG 6 TP NO. 1 SIGNAL K22 20BR/OR Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6912 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6913 Component Location - 10 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6914 Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (5.7L) Pin Description Circuit 1 TP NO. 1 SIGNAL K22 20BR/OR 2 5 VOLT SUPPLY F855 20PK/YL 3 ETC MOTOR (+) K447 20TN/YL 4 TP NO. 2 SIGNAL K122 20BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6915 5 ETC MOTOR (-) K448 20TN/OR 6 TP SENSOR RETURN K922 20BR/DB Component Location - 8 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6916 Component Location - 10 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6917 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6918 Throttle Body: Diagrams Component ID: 495 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (3.7L) Pin Description Circuit 1 ETC MOTOR (+) K447 20TN/YL 2 5 VOLT SUPPLY F855 20PK/YL 3 TP SENSOR RETURN K922 20BR/DB 4 ETC MOTOR (-) K448 20TN/OR 5 TP NO. 2 SIGNAL K122 20BR/DG 6 TP NO. 1 SIGNAL K22 20BR/OR Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6919 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6920 Component Location - 10 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6921 Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (5.7L) Pin Description Circuit 1 TP NO. 1 SIGNAL K22 20BR/OR 2 5 VOLT SUPPLY F855 20PK/YL 3 ETC MOTOR (+) K447 20TN/YL 4 TP NO. 2 SIGNAL K122 20BR/DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6922 5 ETC MOTOR (-) K448 20TN/OR 6 TP SENSOR RETURN K922 20BR/DB Component Location - 8 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6923 Component Location - 10 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 6924 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description Intercooler: Description and Operation Description DESCRIPTION The charge air system consists of the charge air cooler piping, charge air cooler and intake air grid heater. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description > Page 6930 Intercooler: Description and Operation Operation OPERATION 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Page 6931 Intercooler: Testing and Inspection CHARGE AIR COOLER SYSTEM - LEAKS Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system. The following procedure outlines how to check for leaks in the charge air cooler system. This procedure can also be used to check for leaks in the wastegate signal line or the wastegate canister. 1. Loosen clamp and remove air inlet hose from turbocharger. 2. Insert Special Tool 9022 Adapter and tool 9860 into the turbocharger inlet. Tighten tool clamp to 8 Nm (72 in. lbs.). CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, severe damage to the charge air cooler system may occur. 3. Connect a regulated air supply to air fitting on Tool 9022 Adapter. Set air pressure to a Maximum of 138 kPa (20 psi). 4. Using soapy water check the rubber sleeves, charge air cooler and intake manifold for leaks. 5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal Intercooler: Service and Repair Removal REMOVAL WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT. 1. Disconnect the battery negative cables. 2. Discharge the A/C system. 3. Remove the transmission auxiliary cooler. 4. Remove intake air tubing from the charge air cooler. 5. Remove the charge air cooler bolts. Pivot the charge air cooler forward and up to remove. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 6934 Intercooler: Service and Repair Cleaning CLEANING CAUTION: Do not use caustic or acid based cleaners to clean the charge air cooler. Damage to the charge air cooler will result. NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced. NOTE: Charge air cooler must be a room temperature for this procedure. 1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally. 2. Remove charge air cooler. 3. Position the charge air cooler so the inlet and outlet tubes are vertical. 4. Flush the cooler internally with solvent such as mineral spirits in the direction opposite of normal air flow. 5. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. 6. Continue flushing until all debris or oil are removed. 7. Rinse the cooler with hot soapy water to remove any remaining solvent. 8. Rinse thoroughly with clean water and blow dry with compressed air. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 6935 Intercooler: Service and Repair Inspection INSPECTION Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found. Pressure test the charge air cooler, using Charge Air Cooler Tester Kit No. 3824556. This kit is available through Cummins(R) Service Products. Instructions are provided with the kit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 6936 Intercooler: Service and Repair Installation INSTALLATION 1. Position the charge air cooler. Install the bolts and tighten to 2 Nm (17 in. lbs.) torque. 2. Install the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 Nm (95 in. lbs.) torque. 3. Install the transmission auxiliary cooler (if equipped). 4. Install the A/C condenser (if A/C equipped). 5. Connect the battery negative cables. 6. Start engine and check for boost system leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 6941 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 6942 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6945 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6946 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 6947 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 6951 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 6952 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 6953 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations Turbocharger Vane Actuator: Locations Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 SMART POWER RELAY FEED F348 16PK/OR 2 ACTUATOR GROUND K972 18DB/TN 3 ACTUATOR HIGH DATA LINK D130 18BR/VT 4 ACTUATOR LOW DATA LINK D131 18WT/LG Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 6957 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 6958 Turbocharger Vane Actuator: Diagrams Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 SMART POWER RELAY FEED F348 16PK/OR 2 ACTUATOR GROUND K972 18DB/TN 3 ACTUATOR HIGH DATA LINK D130 18BR/VT 4 ACTUATOR LOW DATA LINK D131 18WT/LG Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 6959 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Description and Operation Wastegate Actuator: Description and Operation DESCRIPTION - 6.7L ELECTRONICALLY CONTROLLED ACTUATOR The Electronically Controlled Actuator is mounted to the turbocharger bearing housing. The actuator consists of an integrated controller and a gear train that controls the position of the sliding nozzle ring. The actuator uses a signal from the Engine Control Module (ECM) to control the relationship between the sliding nozzle ring and turbine blades. Moving the nozzle ring rearward or forward redirects the exhaust flow so that the turbine wheel spins faster or slower as needed - If the sliding nozzle is moved rearward, the turbocharger builds more pressure (turbine wheel moves faster) - If the sliding nozzle is moved forward, the turbocharger builds less pressure (turbine wheel moves slower) VGT EXHAUST BRAKE The VGT Exhaust Brake works in conjunction with the engine and transmission to provide an integrated braking system to help slow the vehicle. This is commonly referred to as exhaust braking. Braking power is achieved by modulating the sliding nozzle ring to restrict the flow of exhaust gasses from the engine, this will create high back pressure on the engine. The high back pressure creates a high level of resistance to the motion of the pistons within the engine and this resistance is used to reduce engine speed and thus vehicle. The exhaust brake feature will only function when the Exhaust Brake Switch to the ON position. With the switch in the ON Position and the vehicle moving faster then 5 MPH; the exhaust brake will automatically operate when pressure is removed from the accelerator pedal allowing the ECM to see 0% throttle and 0% fuel delivery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal Wastegate Actuator: Service and Repair Removal 6.7L DIESEL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Drain cooling system. 4. Remove air filter housing. 5. Disconnect turbocharger actuator electrical connector (1). 6. Remove turbocharger actuator mounting bolts (3). 7. Remove turbocharger actuator (2). 8. Clean mounting surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal > Page 6965 Wastegate Actuator: Service and Repair Installation INSTALLATION 1. Clean turbocharger actuator housing and turbocharger mounting surfaces. 2. Position turbocharger actuator in engine compartment so gear will be free to rotate. 3. Connect turbocharger actuator electrical connector. 4. Connect negative battery cable. 5. Using a scan tool, perform TURBO ACTUATOR PRE-ALIGN. NOTE: Do not turn key OFF after performing TURBO ACTUATOR PRE-ALIGN procedure. This holds the actuator gear in position for installation. CAUTION: Use only turbocharger actuator grease. Use of any other type of grease or too much grease may result in damage to turbocharger. 6. Apply grease to turbocharger actuator sector gear in a line across center of all teeth. 7. Install O-ring on turbocharger actuator. 8. Install guide pins on turbocharger. 9. Rotate turbocharger sector gear clockwise and insert small end of turbocharger actuator alignment tool (supplied with new actuator) or 3.175 mm (1/8 in.) drill, through sector gear until it engages the alignment hole in turbocharger bearing housing and sector gear will not rotate. If alignment pin does not engage hole in turbocharger bearing housing, variable geometry mechanism is not opening completely. 10. Remove pin from turbocharger actuator sector gear. Turbocharger actuator sector gear must stay in this position, rotated fully clockwise while installing actuator. 11. Position turbocharger actuator on guide pins and install. 12. Install two mounting screws. Hand tighten only. 13. Remove guide pins. Install remaining two mounting screws. Tighten mounting screws in a cross pattern to 11 Nm (96 in. lbs.). 14. Using scan tool, perform TURBO ACTUATOR SELF CALIBRATE procedure. NOTE: If the TURBO ACTUATOR SELF CALIBRATE procedure fails, remove actuator and repeat installation one additional time. If this fails to clear error, replace turbocharger. 15. Place ignition in the OFF position. 16. Install air filter housing. 17. Fill cooling system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations Wastegate Solenoid: Locations Component ID: 448 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A WASTEGATE SOLENOID CONTROL K139 18DB B FUSED B(+) A212 18PK/YL Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6969 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6970 Wastegate Solenoid: Diagrams Component ID: 448 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A WASTEGATE SOLENOID CONTROL K139 18DB B FUSED B(+) A212 18PK/YL Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6971 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6982 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6983 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6984 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6985 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6986 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6987 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6988 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6989 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6990 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6991 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6992 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6993 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6994 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 6997 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7000 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Description and Operation > Description Condenser: Description and Operation Description DESCRIPTION One coil capacitor (1) is used. It is located in the right-rear section of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Description and Operation > Description > Page 7005 Condenser: Description and Operation Operation OPERATION The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal Condenser: Service and Repair Removal REMOVAL The coil capacitor is located in the right-rear section of the engine compartment. It is attached with a mounting stud and nut. 1. Disconnect electrical connector (5) at capacitor. 2. Remove mounting nut and remove ground strap. 3. Remove capacitor (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal > Page 7008 Condenser: Service and Repair Installation INSTALLATION 1. Position capacitor (1) to mounting stud (2). 2. Position ground strap (3) to mounting stud (2). 3. Tighten nut (4) to 7 Nm (60 in. lbs.) torque. 4. Connect electrical connector (5) to coil capacitor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7012 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7013 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7014 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7015 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7016 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7017 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7018 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7019 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7020 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7021 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7022 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7023 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7024 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7025 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7026 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7027 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7028 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7029 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7030 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7031 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7032 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7033 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7034 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7035 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7036 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7037 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7038 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7039 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7040 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7041 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7042 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7043 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7044 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 7047 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7050 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 7055 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7060 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7061 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7062 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7063 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7064 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7065 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7066 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7067 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7068 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7069 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7070 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7071 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7072 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 7075 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: 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 tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7078 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7082 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7083 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7084 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7085 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7086 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7087 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7088 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7089 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7090 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7091 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7092 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7093 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7094 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7095 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7096 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7097 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7098 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7099 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7100 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7101 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7102 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7103 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7104 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7105 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7106 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7107 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7108 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7109 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7110 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7111 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7112 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7113 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7114 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 7117 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: 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 tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7120 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 7126 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 7131 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description Wait To Start Light: Description and Operation Description DESCRIPTION A wait-to-start indicator is only found in the instrument clusters for vehicles equipped with an optional diesel engine. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The wait-to-start indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Diesel Preheat in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The wait-to-start indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description > Page 7137 Wait To Start Light: Description and Operation Operation OPERATION The wait-to-start indicator gives an indication to the vehicle operator when the air temperature within the diesel engine intake manifold is too cool for efficient and reliable engine starting, and that the intake air heater grids are energized in their pre-heat operating mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The wait-to-start indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the wait-to-start indicator for the following reasons: - Wait-To-Start Indicator Lamp-On Message - Each time the cluster receives an electronic wait-to-start indicator lamp-ON message from the ECM indicating that the air temperature within the intake manifold is too cool for efficient and reliable engine starting, the wait-to-start indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message, until the ECM detects that the engine is running or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the wait-to-start indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ECM continually monitors the engine intake air temperature sensor to determine when the intake air heater grids should be energized in their pre-heat operating mode. The ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the wait-to-start indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the engine intake air temperature sensor, the intake air heater grid control circuits, the ECM, the EMIC, the CAN data bus or the electronic communication related to wait-to-start indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7145 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7148 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7153 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7154 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7155 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7156 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7157 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7158 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7159 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7160 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7163 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7164 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7165 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7166 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7167 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7168 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7169 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7170 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7173 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7176 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7180 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7181 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7182 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7183 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7184 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7189 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7190 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7191 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7192 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7193 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7194 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7195 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7196 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7197 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7198 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7201 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7202 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7203 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7204 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7205 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7206 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7207 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7208 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 7211 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7214 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 7218 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7221 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7227 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7228 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7233 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7234 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7235 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7236 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7237 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7240 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7241 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7242 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7243 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7244 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7249 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7250 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7251 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7252 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7253 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7254 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7255 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7256 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7257 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7258 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7259 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7260 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7261 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7264 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7265 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7266 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7267 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7270 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7271 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7272 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7273 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7274 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7275 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7282 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7283 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7284 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 7289 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7295 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7296 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7297 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 7302 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7313 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7314 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7319 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7320 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7321 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7322 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7328 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7329 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7334 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7335 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7336 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7337 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7338 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7339 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7340 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7341 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7342 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7343 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7344 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7345 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7346 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7347 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7350 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7351 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7352 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7353 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7354 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7355 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 7356 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Transmission Control System Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7386 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7387 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7388 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7389 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7390 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7393 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7394 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7395 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7396 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7402 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7403 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7404 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 7407 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 7410 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7414 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7415 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7416 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7417 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7420 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7421 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7422 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7423 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7424 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7425 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7426 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7431 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7432 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7433 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7434 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7435 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7436 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7437 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7438 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7439 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7440 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7441 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7444 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7445 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7446 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7447 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7448 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7449 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7450 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7451 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7452 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7453 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7454 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7457 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7458 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7459 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7460 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 7461 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7464 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7465 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7466 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7467 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7468 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7473 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7474 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7475 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7476 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7477 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7478 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7479 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7480 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7481 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7482 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7483 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7484 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7485 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7486 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7487 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7488 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7489 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7490 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7491 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7494 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7495 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7496 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7497 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7498 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7499 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7500 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7501 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7502 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7503 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7504 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7505 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7506 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7507 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7508 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7509 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7510 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7511 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7512 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION 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. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7515 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7516 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7519 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7520 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7521 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7522 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7526 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7527 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7528 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 7538 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7543 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7544 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7545 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7546 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7547 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7548 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7549 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7552 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7553 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7554 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7555 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7556 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7557 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7558 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7563 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7564 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7565 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7566 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7567 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7568 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7569 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7570 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7571 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7574 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7575 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7576 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7577 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7578 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7579 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7580 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7581 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7582 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7585 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7586 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7587 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7588 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7589 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7590 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7591 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7592 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7593 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 7596 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7601 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7602 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7603 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7606 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7607 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7608 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 7611 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7620 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7621 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7622 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7623 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7624 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7625 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7626 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7631 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7632 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7633 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7634 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7635 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7636 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7637 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 7643 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7648 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7649 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7650 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7651 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7656 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7657 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7662 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7663 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7668 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7669 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7670 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7671 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: Customer Interest Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7676 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7677 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7683 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 7688 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7693 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7694 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7695 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7696 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7701 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7702 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7703 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7704 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7705 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7706 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7707 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7712 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7713 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7718 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7719 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7724 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7725 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7726 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7727 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7728 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7729 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7730 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7735 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7736 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7737 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7738 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7743 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7744 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7750 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 7755 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7760 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7761 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7762 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7763 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7768 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7769 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7774 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7775 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7780 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7781 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7782 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 7783 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7788 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 7789 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7795 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7800 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7801 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7802 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7803 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7804 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7805 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7806 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7811 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7812 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7813 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7814 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7815 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7816 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7817 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7825 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7828 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7833 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7834 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7835 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7836 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7837 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7838 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7839 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7840 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7843 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7844 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7845 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7846 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7847 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7848 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7849 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7850 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7853 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7856 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7860 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7861 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7862 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7863 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7864 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7869 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7870 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7871 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7872 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7873 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7874 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7875 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7876 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7877 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7878 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7881 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7882 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7883 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7884 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7885 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7886 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7887 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7888 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 7891 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7894 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 7898 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7901 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7907 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7908 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7913 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7914 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7915 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7916 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7917 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7920 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7921 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7922 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7923 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7924 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7929 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7930 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7931 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7932 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7933 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7935 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7936 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7937 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7938 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7939 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7940 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7941 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7944 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7945 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7946 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7947 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7950 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7951 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7952 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7953 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7954 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7961 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7964 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7969 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7970 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7971 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7972 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7973 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7974 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7975 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7976 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7979 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7980 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7981 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7982 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7983 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7984 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7985 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7986 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7989 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7992 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7996 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7997 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7998 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7999 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8000 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8005 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8006 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8007 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8008 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8009 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8010 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8011 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8012 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8013 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8014 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8017 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8018 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8019 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8020 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8021 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8022 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8023 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8024 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 8027 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8030 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 8034 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8037 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Accumulator: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components. By adjusting the spring pressure acting on the regulator valve, transmission line pressure can be adjusted. Upper Housing Control Valve Locations - Regulator valve (2) - Switch valve (3) - Regulator valve spring (4) - Kickdown valve (5) - Kickdown detent (6) - Throttle valve and spring (7) - Manual valve (8) - 1-2 Governor plug (9) - Throttle pressure plug (11) - 2-3 Governor plug (12) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8042 - Shuttle valve primary spring (13) Shuttle and Boost Valve Locations - Boost Valve (3) - Boost valve plug (4) - Shuttle valve (9) - Shuttle valve throttle plug (12) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8043 Upper Housing Shift Valve and Pressure Plug Locations - 1-2 shift valve (2) - 1-2 control valve - 2-3 shift valve - 2-3 throttle plug - Throttle pressure plug - Limit valve and spring Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8044 Lower Housing Shift Valves and Springs - 3-4 shift valve - 3-4 timing valve - 3-4 quick fill valve - 3-4 accumulator - Converter clutch lock-up valve - Converter clutch lock-up timing valve Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8045 CHECK BALLS REGULATOR VALVE Regulator Valve in Park Position The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid. The pressure regulator valve is located in the valve body near the manual valve. The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the left. This closes a dump (vent) that is used to lower pressure. The closing of the dump will cause the oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the right, opening the dump and lowering oil pressure. The result is spring pressure working against oil pressure to maintain the oil at specific pressures. With the engine running, fluid flows from the pump to the pressure regulator valve, manual valve, and the interconnected circuits. As fluid is sent through passages to the regulator valve, the pressure pushes the valve to the right against the large spring. It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug. With the gear selector in the PARK position, fluid recirculates through the regulator and manual valves back to the sump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8046 Regulator Valve in Neutral Position Meanwhile, the torque converter is filled slowly. In all other gear positions, fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter. After the torque converter and switch valve fill with fluid, the switch valve becomes the controlling metering device for torque converter pressure. The regulator valve then begins to control the line pressure for the other transmission circuits. The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land #2 (land #1 being at the far right of the valve in the diagram). As fluid leaks past the land, it moves into a groove connected to the filter or sump. As the land meters the fluid to the sump, it causes the pressure to reduce and the spring decreases the size of the metering passage. When the size of the metering passage is reduced, the pressure rises again and the size of the land is increased again. Pressure is regulated by this constant balance of hydraulic and spring pressure. Regulator Valve in Drive Position The metering at land #2 establishes the line pressure throughout the transmission. It is varied according to changes in throttle position and the transmission's internal condition within a range of 57-94 psi (except in REVERSE). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8047 Regulator Valve in Reverse Position The regulated line pressure in REVERSE is held at much higher pressures than in the other gear positions: 145-280 psi. The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land #4. With this pressure blocked, there is less area for pressure to act on to balance the force of the spring on the right. This allows line pressure to push the valve train to the right, reducing the amount of fluid returned to the pump's inlet, increasing line pressure. KICKDOWN VALVE Kickdown Valve - Wide Open Throttle When the throttle valve is as far over to the left as it can go, the maximum line pressure possible will enter the throttle pressure circuit. In this case, throttle pressure will equal line pressure. With the kickdown valve pushed into the bore as far as it will go, fluid initially flows through the annular Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8048 groove of the 2-3 shift valve (which will be in the direct drive position to the right). After passing the annular groove, the fluid is routed to the spring end of the 2-3 shift valve. Fluid pressure reacting on the area of land #1 overcomes governor pressure, downshifting the 2-3 shift valve into the kickdown, or second gear stage of operation. The valve is held in the kickdown position by throttle pressure routed from a seated check ball (#2). Again, if vehicle speed is low enough, throttle pressure will also push the 1-2 shift valve left to seat its governor plug, and downshift to drive breakaway. KICKDOWN LIMIT VALVE Kickdown Limit Valve - Low Speeds The purpose of the limit valve is to prevent a 3-2 downshift at higher speeds when a part-throttle downshift is not desirable. At these higher speeds only a full throttle 3-2 downshift will occur. At low road speeds the limit valve does not come into play and does not affect the downshifts. Kickdown Limit Valve - High Speeds As the vehicle's speed increases, the governor pressure also increases. The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore. This pushes the valve upward against the spring and bottoms the valve against the top of the housing. With the valve bottomed against the housing, the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve. When the supply of throttle pressure has been shut off, the 3-2 part throttle downshift plug becomes inoperative, because no pressure is acting on its reaction area. 1-2 SHIFT VALVE 1-2 Shift Valve - Before Shift Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8049 The 1-2 shift valve assembly, or mechanism, consists of: the 1-2 shift valve, governor plug, and a spring on the end of the valve. After the manual valve has been placed into a forward gear range, line pressure is directed to the 1-2 shift valve. As the throttle is depressed, throttle pressure is applied to the right side of the 1-2 shift valve assembly. With throttle pressure applied to the right side of the valve, there is now both spring pressure and throttle pressure acting on the valve, holding it against the governor plug. As the vehicle begins to move and build speed, governor pressure is created and is applied to the left of the valve at the governor plug. 1-2 Shift Valve - After Shift When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve, the valve will begin to move over to the right. As the valve moves to the right, the middle land of the valve will close off the circuit supplying the throttle pressure to the right side of the valve. When the throttle pressure is closed off, the valve will move even farther to the right, allowing line pressure to enter another circuit and energize the front servo, applying the front band. The governor plug serves a dual purpose: - It allows the shift valves to move either left or right, allowing both upshifts and downshifts. - When in a manual selection position, it will be hydraulically "blocked" into position so no upshift can occur. The physical blocking of the upshift while in the manual "1" position is accomplished by the directing of line pressure between both lands of the governor plug. The line pressure reacts against the larger land of the plug, pushing the plug back against the end plate overcoming governor pressure. With the combination of the line pressure and spring pressure, the valve cannot move, preventing any upshift. 1-2 SHIFT CONTROL VALVE 1-2 Shift Control Valve It contains a valve with four lands and a spring. It is used as both a "relay" and "balanced" valve. The valve has two specific operations: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8050 - Aid in quality of the 1-2 upshift. - Aid in the quality and timing of the 3-2 kickdown ranges. When the manual valve is set to the DRIVE position and the transmission is in the first or second gear range, 1-2 shift control or "modulated throttle pressure" is supplied to the middle of the accumulator piston by the 1-2 shift control valve. During the 1-2 upshift, this pressure is used to control the kickdown servo apply pressure that is needed to apply the kickdown and accumulator pistons. Thus, the 1-2 shift point is "cushioned" and the quality is improved. During a WOT kickdown, kickdown pressure is applied between the kickdown valve and the 1-2 shift control valve. This additional pressure is directed to the 1-2 shift control's spring cavity, adding to the spring load on the valve. The result of this increased "modulated" throttle pressure is a firmer WOT upshift. 2-3 SHIFT VALVE 2-3 Shift Valve - Before Shift The 2-3 shift valve mechanism consists of the 2-3 shift valve, governor plug and spring, and a throttle plug. After the 1-2 shift valve has completed its operation and applied the front band, line pressure is directed to the 2-3 shift valve through the connecting passages from the 1-2 shift valve. The line pressure will then dead-end at land #2 until the 2-3 valve is ready to make its shift. Now that the vehicle is in motion and under acceleration, there is throttle pressure being applied to the spring side of the valve and between lands #3 and #4. 2-3 Shift Valve - After Shift As vehicle speed increases, governor pressure increases proportionately, until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve. Since the throttle pressure end of the 2-3 shift valve is larger in diameter than the 1-2 shift valve, the 2-3 shift will always happen at a greater speed than the 1-2 shift. When this happens, the governor plug is forced against the shift valve moving it to the right. The shift valve causes land #4 to close the passage supplying throttle pressure to the 2-3 shift valve. Without throttle pressure present in the circuit now, the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8051 governor plug will push the valve over far enough to bottom the valve in its bore. This allows land #2 to direct line pressure to the front clutch. After the shift, line pressure is directed to the release side of the kickdown servo. This releases the front band and applies the front clutch, shifting into third gear or direct drive. The rear clutch remains applied, as it has been in the other gears. During a manual "1" or manual "2" gear selection, line pressure is sent between the two lands of the 2-3 governor plug. This line pressure at the governor plug locks the shift valve into the second gear position, preventing an upshift into direct drive. The theory for the blocking of the valve is the same as that of the 1-2 shift valve. If the manual "2" or manual "1" gear position is selected from the drive position, the PCM will control the timing of the downshift by targeting for a high governor pressure. When a safe vehicle speed is reached, the PCM will switch to its normal control governor curve and the downshift will occur. 3-4 SHIFT VALVE 3-4 Shift Valve Before Shift The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8052 3-4 Shift Valve After Shift Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. 3-4 TIMING VALVE 3-4 Shift Valve After Shift The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve or the converter clutch valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8053 3-4 Shift Valve Before Shift After the shift, the timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from downshifting while either the overdrive clutch or converter clutch is applied. 3-4 QUICK FILL VALVE 3-4 Shift Valve Before Shift The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8054 3-4 Shift Valve After Shift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. THROTTLE VALVE Throttle Valve In all gear positions, the throttle valve is being supplied with line pressure. The throttle valve meters and reduces the line pressure that now becomes throttle pressure. The throttle valve is moved by a spring and the kickdown valve, which is mechanically connected to the throttle. The larger the throttle opening, the higher the throttle pressure (to a maximum of line pressure). The smaller the throttle opening, the lower the throttle pressure (to a minimum of zero at idle). As engine speed increases, the increase in pump speed increases pump output. The increase in pressure and volume must be regulated to maintain the balance within the transmission. To do this, throttle pressure is routed to the reaction area on the right side of the throttle pressure plug (in the regulator valve). The higher engine speed and line pressure would open the vent too far and reduce line pressure too much. Throttle pressure, which increases with engine speed (throttle opening), is used to oppose the movement of the pressure valve to help control the metering passage at the vent. The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve. The larger spring at the right closes the regulator valve passage and maintains or increases line pressure. The increased line pressure works against the reaction area of the line pressure plug and the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8055 reaction area left of land #3 simultaneously moves the regulator valve train to the right and controls the metering passage. The kickdown valve, along with the throttle valve, serve to delay upshifts until the correct vehicle speed has been reached. It also controls downshifts upon driver demand, or increased engine load. If these valves were not in place, the shift points would be at the same speed for all throttle positions. The kickdown valve is actuated by a cam connected to the throttle. This is accomplished through either a linkage or a cable. The cam forces the kickdown valve toward the throttle valve compressing the spring between them and moving the throttle valve. As the throttle valve land starts to uncover its port, line pressure is "metered" out into the circuits and viewed as throttle pressure. This increased throttle pressure is metered out into the circuits it is applied to: the 1-2 and 2-3 shift valves. When the throttle pressure is high enough, a 3-2 downshift will occur. If the vehicle speed is low enough, a 2-1 downshift will occur. SWITCH VALVE Switch Valve - Torque Converter Unlocked When the transmission is in Drive Second before the TCC application occurs, the pressure regulator valve is supplying torque converter pressure to the switch valve. The switch valve directs this pressure through the transmission input shaft, into the converter, through the converter, back out between the input shaft and the reaction shaft, and back up to the switch valve. From the switch valve, the fluid pressure is directed to the transmission cooler, and lubrication pressure returns from the cooler to lubricate different portions of the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8056 Switch Valve - Torque Converter Locked MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the side of the valve body. The valve is connected mechanically by either a cable or linkage to the gearshift mechanism. The valve is held in each of its positions by a spring-loaded roller or ball that engages the "roostercomb" of the manual valve lever. Manual Valve Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8057 Once the TCC control valve has moved to the right, line pressure is directed to the tip of the switch valve, forcing the valve to the right. The switch valve now vents oil from the front of the piston in the torque converter, and supplies line pressure to the (rear) apply side of the torque converter piston. This pressure differential causes the piston to apply against the friction material, cutting off any further flow of line pressure oil. After the switch valve is shuttled right allowing line pressure to engage the TCC, torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits. CONVERTER CLUTCH LOCK-UP VALVE The torque converter clutch (TCC) lock-up valve controls the back (ON) side of the torque converter clutch. When the PCM energizes the TCC solenoid to engage the converter clutch piston, pressure is applied to the TCC lock-up valve which moves to the right and applies pressure to the torque converter clutch. CONVERTER CLUTCH LOCK-UP TIMING VALVE The torque converter clutch (TCC) lock-up timing valve is there to block any 4-3 downshift until the TCC is completely unlocked and the clutch is disengaged. SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves. When the manual valve is positioned in the Drive range, throttle pressure acts on the throttle plug of the shuttle valve to move it against a spring, increasing the spring force on the shuttle valve. During a part or full throttle 1-2 upshift, the throttle plug is bottomed by throttle pressure, holding the shuttle valve to the right against governor pressure, and opening a by-pass circuit. The shuttle valve controls the quality of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits. During a 3-2 kickdown, fluid discharges through the shuttle by-pass circuit. When the shuttle valve closes the by-pass circuit, fluid discharge is restricted and controlled for the application of the front band. During a 2-3 "lift foot" upshift, the shuttle valve by-passes the restriction to allow full fluid flow through the by-pass groove for a faster release of the band. BOOST VALVE Boost Valve Before Lock-up The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8058 Boost Valve After Lock-up The boost valve also serves to increase line pressure during torque converter lock-up. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8059 Accumulator: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION Valve Body Components The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components: - Solenoid switch valve - Manual valve - Low/reverse shuttle valve - 5 Accumulators Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8060 Check Ball Locations - 7 check balls Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In all other gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8061 Accumulator: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The valve body consists of a two piece aluminum valve body. Extensive electronic control effected by a microcomputer (the automatic transmission electronic control unit) over the hydraulic circuitry enables precise control over gearshifts. The valve body contains valves and pressure sensors that control fluid delivery to the torque converter clutch, forward clutches, and brake clutches. UPPER VALVE BODY UPPER VALVE BODY The upper valve body contains the following components: - 1 = Combined Drain - 2 = Gain change solenoid valve - 3 = Manual valve - 4 = Modulator valve - 5 = Shift solenoid valve No. 3 - 6 = Shift solenoid valve No. 2 - 7 = Shift valve No. 1 LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8062 LOWER VALVE BODY The lower valve body contains the following components: - 1 = Control valve No. 3 - 2 = Shift solenoid valve No. 4 - 3 = Lockup control valve - 4 = Control valve No. 1 - 5 = Control valve No. 2 SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8063 VALVE BODY OIL SWITCH HARNESS There are eight pressure switches and one ATF temperature switch used to inform the Transmission Control Module (TCM) when there is pressure in various hydraulic circuits. Six of them are located on the bottom of the valve body. The remainder are located on the top of the valve body. SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8064 VALVE BODY SOLENOID HARNESS Eight solenoids are used to control various shift functions in the transmission. Four are located on the top of the valve body (3, 4) and the remainder are located on the bottom of the valve body. Operation OPERATION LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8065 LOWER VALVE BODY UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8066 UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8067 SWITCHES AND SOLENOIDS VALVE BODY OIL SWITCH HARNESS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8068 SWITCHES AND SOLENOIDS VALVE BODY SOLENOID HARNESS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8069 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8078 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8079 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8084 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8085 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8086 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8087 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8093 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8094 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8099 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8100 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8101 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8102 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8103 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8104 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8105 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8106 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8107 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8108 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8109 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8110 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8111 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8112 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8115 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8116 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8117 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8118 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8119 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8120 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8121 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8127 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8132 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8133 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8134 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8135 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION Service Fill - 42RLE ............................................................................................................................. ....................................................... 3.8L (4.0 Quarts) Overhaul Fill - 42RLE ...................................... ........................................................................................................................................... 8.3L (8.7 Quarts) Service Fill - 45RFE/545RFE 4X2 .............................................................................................................................................................. 5.2L (5.5 Quarts) 4X4 .......................................................................................................................... .................................................................................... 6.2L (6.5 Quarts) Overhaul - 45RFE/545RFE ....................................................................................................................................................... 14 -16L (14.8-16.9 Quarts) Service Fill - 48RE ............................................................................................................................... ....................................................... 3.8L (4.0 Quarts) Overhaul - 48RE .............................................. ..................................................................................................................... 14 - 16L (14.8 - 16.9 Quarts) Service Fill - 68RFE 4X2 ..................................................................................................................... ....................................................... 5.2L (5.5 Quarts) 4X4 .................................................................. ............................................................................................................................................ 6.2L (6.5 Quarts) Overhaul - 68RFE ................................................................................................................... ............................................ 15.6 - 16.6L (16.4 - 17.5 Quarts) Service Fill - AS68RC .......................................................................................................................... ....................................................... 6.8L (7.2 Quarts) Overhaul - AS68RC ......................................... ......................................................................................................................................... 13L (13.74 Quarts) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 8138 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 8141 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 8142 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8145 transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8146 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8147 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid, refer to FLUID - STANDARD PROCEDURE and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8148 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8149 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8150 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8151 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8152 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8153 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8154 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8155 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8156 Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8161 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8162 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8163 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8164 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8165 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8166 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission Fluid Pan: Specifications 68RFE Automatic Transmission Fluid Pan Tighten bolts to .................................................................................................................... ..................................................... 12 Nm (105 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 8171 Fluid Pan: Specifications 48RE Automatic Transmission Transmission oil pan NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. Tighten the bolts to .............................................................................................................................. ............................................... 13.6 Nm (125 in.lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 8172 Fluid Pan: Specifications AS68RC Automatic Transmission Fluid Pan Tighten bolts to .................................................................................................................... ......................................................... 7 Nm (62 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8176 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8177 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8178 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8181 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 8184 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid Pump: Testing and Inspection 68RFE Automatic Transmission STANDARD PROCEDURE - OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) ATF +4, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. 2. Plug the inlet to the oil cooler. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 3. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5° C (220° F) for this test. 4. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/68RFE Automatic Transmission/Hydraulic Pressure Test 5. Unplug the oil cooler inlet. 6. Re-connect the To cooler line to the transmission cooler inlet. 7. Refill the transmission to proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 8189 Fluid Pump: Testing and Inspection AS68RC Automatic Transmission OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) AS68RC, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed one (1) quart or internal damage to the transmission may occur. 2. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5° C (220° F) for this test. 3. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/AS68RC Automatic Transmission/Hydraulic Pressure Test 4. Install the To cooler line to the transmission cooler inlet. 5. Refill the transmission to proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description Governor: Description and Operation Description DESCRIPTION Governor pressure is controlled electronically. Components used for governor pressure control include: - Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle position sensor (TPS) - Transmission speed sensor - Powertrain control module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve (2) is a duty-cycle solenoid which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate. GOVERNOR BODY, TRANSFER PLATE, AND PRESSURE SENSOR The governor pressure sensor (2) measures output pressure of the governor pressure solenoid valve. The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body (1). The body is bolted to the lower side of the transfer plate. GOVERNOR PRESSURE CURVES There are four governor pressure curves programmed into the transmission control module. The different curves allow the control module to adjust governor pressure for varying conditions. One curve is used for operation when fluid temperature is at, or below, -1°C (30°F). A second curve is used when fluid temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used during wide-open throttle operation. The fourth curve is used when driving with the transfer case in low range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 8194 Governor: Description and Operation Operation OPERATION Compensation is required for performance variations of two of the input devices. Though the slope of the transfer functions is tightly controlled, offset may vary due to various environmental factors or manufacturing tolerances. The pressure transducer is affected by barometric pressure as well as temperature. Calibration of the zero pressure offset is required to compensate for shifting output due to these factors. Normal calibration will be performed when sump temperature is above 50 degrees F, or in the absence of sump temperature data, after the first 10 minutes of vehicle operation. Calibration of the pressure transducer offset occurs each time the output shaft speed falls below 200 RPM. Calibration shall be repeated each 3 seconds the output shaft speed is below 200 RPM. A 0.5 second pulse of 95% duty cycle is applied to the governor pressure solenoid valve and the transducer output is read during this pulse. Averaging of the transducer signal is necessary to reject electrical noise. Under cold conditions (below 50 degrees F sump), the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0.5 second calibration pulse. Calibration pulses are continued during this period, however the transducer output valves are discarded. Transducer offset must be read at key-on, under conditions which promote a stable reading. This value is retained and becomes the offset during the "cold" period of operation. GOVERNOR PRESSURE SOLENOID VALVE The inlet side of the solenoid valve is exposed to normal transmission line pressure. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure. The powertrain control module (PCM) turns on the trans control relay which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed. NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load condition. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. WIDE OPEN THROTTLE OPERATION In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 8195 TRANSFER CASE LOW RANGE OPERATION On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares electronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal Governor: Service and Repair Removal REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor (1) and solenoid (2). 4. Remove screws holding pressure solenoid retainer (1) to governor body (2). 5. Separate solenoid retainer from governor. 6. Pull solenoid (1) from governor body (3). 7. Pull pressure sensor from governor body. 8. Remove bolts holding governor body to valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 8198 9. Separate governor body (1) from valve body. 10. Remove governor body gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 8199 Governor: Service and Repair Installation INSTALLATION Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. 1. Place gasket (2) in position on back of governor body (1). 2. Place governor body in position on valve body. 3. Install bolts to hold governor body to valve body. 4. Lubricate O-ring on pressure sensor with transmission fluid. 5. Align pressure sensor to bore in governor body. 6. Push pressure sensor into governor body. 7. Lubricate O-ring (2), on pressure solenoid (1), with transmission fluid. 8. Align pressure solenoid (1) to bore in governor body (3). 9. Push solenoid into governor body. 10. Place solenoid retainer (1) in position on governor (2). 11. Install screws to hold pressure solenoid retainer to governor body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 8200 12. Engage wire connectors into pressure sensor (1) and solenoid (2). 13. Install transmission fluid pan and (new) filter. 14. Lower vehicle and road test to verify repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8206 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8207 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8208 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 8213 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 8219 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8222 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8227 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8228 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8229 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 8233 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 8234 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 8235 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 8236 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8239 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8240 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8241 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8242 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8243 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8244 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8245 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8250 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8251 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8252 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8253 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8254 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8255 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8256 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8257 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8260 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8261 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8262 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8263 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8264 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8265 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8266 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8267 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 8270 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8273 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8283 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8284 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8289 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8290 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8291 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8292 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8298 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8299 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8304 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8305 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8306 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8307 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8308 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8309 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8310 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8311 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8312 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8313 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8314 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8315 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8316 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8317 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8320 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8321 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8322 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8323 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8324 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8325 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8326 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Transmission Control System Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission Seals and Gaskets: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. On 4WD vehicles remove the transfer case from the transmission, on 2WD vehicles remove the propeller shaft. 2. Using a pry tool, remove the output shaft seal. Installation INSTALLATION NOTE: On the 2WD models use Seal Installer 8154 with Handle C-4171. SEAL INSTALLER 10020 1. Clean the seal bore in the extension housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the extension housing using Handle C-4171 (1) and Seal Installer 10020 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 8356 Seals and Gaskets: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with a screw mounted in a slide hammer. Installation INSTALLATION 1. Place seal in position on overdrive housing. 2. Drive seal into overdrive housing with Seal Installer 8154 (1) or 9037 (1) if equipped with a dust boot and Handle C-4171. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 8357 Seals and Gaskets: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove the transmission from the vehicle. 2. Remove the torque converter from the transmission torque converter housing. 3. Use a pry tool to remove oil pump seal. Installation INSTALLATION NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. 1. Clean and inspect oil pump seal seat. Then install seal using Converter Hub Seal Installer 9987. 2. Clean and inspect torque converter hub. If nicks, scratches or hub wear are found, torque converter replacement will be required. CAUTION: If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for cracks. If any cracks are found replace the drive plate. Do not attempt to repair a cracked drive plate. Always use new torque converter to drive plate bolts. 3. Apply a light film of MOPAR(R) AS68RC ATF oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing. 4. Install the transmission into the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8362 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8363 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8364 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8367 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 8370 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8374 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8375 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8376 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8377 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8380 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8381 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8382 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8383 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8384 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8385 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8386 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8391 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8392 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8393 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8394 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8395 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8396 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8397 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8398 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8399 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8400 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8401 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8404 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8405 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8406 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8407 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8408 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8409 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8410 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8411 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8412 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8413 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8414 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8417 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8418 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8419 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8420 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 8421 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8424 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8425 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8426 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8427 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8428 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8433 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8434 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8435 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8436 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8437 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8438 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8439 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8440 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8441 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8442 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8443 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8444 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8445 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8446 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8447 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8448 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8449 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8450 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8451 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8454 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8455 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8456 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8457 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8458 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8459 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8460 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8461 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8462 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8463 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8464 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8465 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8466 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8467 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8468 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8469 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8470 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8471 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8472 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION 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. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8475 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8476 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8479 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8480 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8481 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8482 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8486 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8487 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8488 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8493 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8494 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8495 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8496 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8497 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8502 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8503 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8504 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8505 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8506 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8507 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8508 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8509 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8510 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8511 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8514 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8515 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8516 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8517 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8518 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8519 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8520 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8521 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 8524 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8527 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shifter A/T: Description and Operation 42RLE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides FIRST gear only. Overrun braking is also provided in this range. MANUAL SECOND (2) range provides FIRST and SECOND gear only. DRIVE range provides FIRST, SECOND, THIRD and OVERDRIVE FOURTH gear ranges. The shift into OVERDRIVE FOURTH gear range occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The FOURTH gear upshift occurs automatically when the overdrive selector switch is in the ON position. An upshift to FOURTH gear may not occur or may be delayed in some of the possible shift schedules. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8532 Shifter A/T: Description and Operation 545RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. DRIVE range provides FIRST, SECOND, THIRD, OVERDRIVE FOURTH, and OVERDRIVE FIFTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 or 4-5 shifts. The FOURTH and FIFTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FOURTH or FIFTH gears will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to THIRD is not yet complete. - Vehicle speed is too low for the 3-4 or 4-5 shifts to occur. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8533 Shifter A/T: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides four shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) Operation OPERATION Drive range provides underdrive FIRST, SECOND and THIRD gears, direct FOURTH gear and overdrive FIFTH and SIXTH gears. The shift into overdrive FIFTH and SIXTH gear occurs only after the transmission has completed the shift into FOURTH gear. No other movement of the shift mechanism is required to complete the 4-5 or 5-6 gear shifts. The FOURTH and FIFTH gear upshift occurs automatically unless the Tow/Haul mode is enabled. Upshifts into both overdrive gears, FIFTH and SIXTH, will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8534 Shifter A/T: Description and Operation 48RE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - PARK (P) - REVERSE (R) - NEUTRAL (N) - DRIVE (D) - Manual SECOND (2) - Manual LOW (1) Operation OPERATION Manual LOW (1) range provides first gear only. Overrun braking is also provided in this range. Manual SECOND (2) range provides first and second gear only. DRIVE range provides first, second, third, and overdrive fourth gear ranges. The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position. No upshift to fourth gear will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to third is not yet complete. - Vehicle speed is too low for the 3-4 shift to occur. - Battery temperature is below -5° C (23° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8535 Shifter A/T: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The gear shift mechanism provides seven shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual Third (3) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. MANUAL THIRD range provides first, second and third gear only. DRIVE range provides FIRST, SECOND, THIRD, FOURTH, OVERDRIVE FIFTH, OVERDRIVE SIXTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. The SIXTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FIFTH or SIXTH gears will occur if any of the following are true: - The transmission fluid temperature is below 5° C (41° F). - The shift to Fourth is not yet complete. - Vehicle speed is too low for the 4-5 or 5-6 shifts to occur. - Transfer case is in low range. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal Shifter A/T: Service and Repair Removal REMOVAL 1. Remove the kneeblocker (2) and steering column opening reinforcement (1). 2. Remove the upper and lower column shrouds (1&2). 3. Loosen the column bolts and lower the column enough to allow clearance for the gear shift lever removal. 4. Disconnect the overdrive switch harness (3) (if equipped). 5. Disconnect the shift cable (2) from the shift lever. 6. Remove the gear shift lever mounting screws (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 8538 7. Remove the blocker pin (1) from the inhibit link slot (2) and remove the lever (3) by pulling forward toward the steering wheel and to the left then down. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 8539 Shifter A/T: Service and Repair Installation INSTALLATION 1. Install the lever assembly (3) reversing the way it came out using care to install the pin (2) in the blocker to slider slot (1). 2. The block inhibitor pin and spring (1) should seat into the slider slot (2). 3. Install the mounting screws (1) and tighten to 12 Nm (105 in. lbs.). 4. Cycle the key from ACC to RUN and ensure that the blocker does not stick or bind. 5. Turn the key to the OFF position and ensure that the shifter will not pull from the PARK position. 6. Connect the over drive switch harness (if equipped) (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 8540 NOTE: Route and tie off harness to original location. 7. Connect the shift cable to the lever (2). 8. Ensure the gear shift lever and transmission are in the PARK position and snap the cable adjust clip in place. 9. Install the upper and lower column shrouds (1&2). 10. Install the column back into place and tighten. 11. Install the kneeblocker (2) and steering column reinforcement cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission Shift Cable: Testing and Inspection 42RLE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8546 Shift Cable: Testing and Inspection 545RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8547 Shift Cable: Testing and Inspection 68RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8548 Shift Cable: Testing and Inspection 48RE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8549 Shift Cable: Testing and Inspection AS68RC Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission Shift Cable: Adjustments 68RFE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 8552 Shift Cable: Adjustments 48RE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 8553 Shift Cable: Adjustments AS68RC Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Cable: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8556 Gearshift Cable at Steering Column 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. Gearshift Cable at Steering Column Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8557 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable, and BTSI mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8558 Shift Cable: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8559 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8560 Shift Cable: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8561 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8562 Shift Cable: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. GEARSHIFT CABLE AT THE DASH PANE 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8563 BRAKE TRANSMISSION INTERLOCK MEC 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8564 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8565 Shift Cable: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect the shift cable ball socket (3) at transmission manual shift lever (4) and pull shift cable out of mounting bracket (1). 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8566 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8567 6. Route the gearshift cable through the shift cable mounting bracket (1) and secure the cable by snapping the cable retaining ears into the bracket and by snapping the shift cable ball socket (3) onto the manual shift lever (4) ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 8572 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 8577 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8580 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation Throttle Valve Cable/Linkage: Description and Operation DESCRIPTION Transmission throttle valve cable (1) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (3). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip (2) at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8584 Throttle Valve Cable/Linkage: Adjustments ADJUSTMENTS - THROTTLE VALVE CABLE A correctly adjusted throttle valve cable (1) will cause the throttle lever on the transmission to move simultaneously with the throttle body lever (3) from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that lever on throttle body is at curb idle position. Then verify that the transmission throttle lever is also at idle (fully forward) position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8585 4. Slide cable off attachment stud on throttle body lever. 5. Compare position (B) of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 in.) in either direction (B). - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable Adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. ADJUSTMENT PROCEDURE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8586 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end (3) from attachment stud on throttle lever (1). Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V. cable lock (A) into the UP position. This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1mm). 7. While holding the T.V. cable in the set position push the T.V. cable lock (A) into the down position. This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed Torque Converter: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (4), an overrunning clutch, an impeller (2), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8591 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8592 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8593 torque converter is operational. The stator (1) is located between the impeller (2) and turbine (4) within the torque converter case. TORQUE CONVERTER CLUTCH (TCC) The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) was added to the turbine (5), and a friction material (7) was added to the inside of the front cover (1) to provide this mechanical lock-up. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8594 Torque Converter Fluid Operation The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in a direction that would tend to slow it down. STATOR Stator Operation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8595 Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions the turbine is stationary and the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades (1) and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied or released when fluid is feed or vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in FOURTH gear, and in THIRD gear under various conditions, such as when the O/D switch is OFF, or when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high transmission temperatures are sensed by the PCM. The torque converter clutch may disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8596 Torque Converter: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (2), an overrunning clutch, an impeller (5), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub (3) drives the transmission oil (fluid) pump and contains an O-ring seal (4) to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8597 The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8598 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8599 The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) with friction material (7) was added to the turbine assembly (5) to provide this mechanical lock-up. In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Operation OPERATION The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8600 TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in all gear ranges except first depending on the Tow/Haul and ERS status. In normal operation, the clutch will engage after the shift to fourth gear. If the Tow/Haul mode is enabled, the clutch will engage after the shift to third (direct) gear. The TCM controls the torque converter clutch via the L/R-CC Solenoid. There are four TCC operational modes: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8601 - No EMCC - Partial EMCC - Full EMCC - Gradual EMCC Release NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL EMCC RELEASE This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by slowly decreasing the L/R Solenoid duty cycle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8602 Torque Converter: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an lock-up damper (1), lock-up piston (3 ), pump impeller (4), turbine runner (5), stator (6), and one-way clutch (7). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8603 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8604 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8605 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8606 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed Torque Converter: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be 19mm (0.75 in.) to the rear of the straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8609 Torque Converter: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/1000 grit paper or crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub O-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 25 mm (1in.) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8610 Torque Converter: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove transmission from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. WARNING: Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. TC REMOVAL 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/10000 grit paper or crocus cloth if necessary. Verify that the oil pump seal is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. TC REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8611 1. Lubricate oil pump seal lip and input shaft seal rings with MOPAR(R) AS68RC ATF. WARNING: Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or input shaft seal rings while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Install the transmission into the vehicle. 7. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 28.2 mm (1.12 in.) to rear of straightedge when converter is fully seated. 8. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 9. Install the transmission in the vehicle. 10. Fill the transmission with the recommended fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description Torque Converter Check Valve: Description and Operation Description DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted TOC and the air to oil TOC. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description > Page 8616 Torque Converter Check Valve: Description and Operation Operation DIESEL ENGINE The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have pipe thread on one end, while the opposite end is threaded for a flare fitting, and are threaded into the oil cooler mounted on the side of the engine. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Page 8617 Torque Converter Check Valve: Service and Repair DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted transmission oil cooler and the air to oil transmission oil cooler. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be replaced. If the valve is restricted, installed backwards, or in the wrong line, it will cause an transmission overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an transmission overheating condition and eventual transmission failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 Transmission Control System Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles Transmission Cooler: Description and Operation All Vehicles ALL VEHICLES An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler and Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles > Page 8647 Transmission Cooler: Description and Operation Diesel DIESEL The 5.9L diesel models equipped with an automatic transmission are equipped with a water-to-oil cooler and a separate air-to-oil cooler. Both coolers are supplied as standard equipment on diesel engine powered models when equipped with an automatic transmission. The water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine. The 6.7L model diesel with automatic transmission is equipped with an air-to-oil cooler only. This cooler is located in front of the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler Transmission Cooler: Service and Repair Transmission Oil Cooler Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Remove Charge Air Cooler. 2. Place a drain pan under the oil cooler. 3. Raise the vehicle. 4. Disconnect the oil cooler quick-connect fittings from the transmission lines. 5. Remove the charge air cooler-to-oil cooler bolt. 6. Remove two mounting nuts. 7. Remove the oil cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing. Water To Oil Cooler REMOVAL - WATER TO OIL COOLER CAUTION: If a leak should occur in the water-to-oil cooler mounted to the side of the engine block, engine coolant may become mixed with transmission fluid. Transmission fluid may also enter engine cooling system. Both cooling system and transmission should be drained and inspected in case of oil cooler leakage. 1. Disconnect both battery negative cables. 2. Remove starter. 3. Drain cooling system. 4. Disconnect coolant lines from cooler. NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Disconnect transmission oil lines from cooler. Plug cooler lines to prevent oil leakage. 6. Remove cooler bracket to transmission adapter bolt. 7. Remove wire harness push in clip at bottom of coolant bracket. 8. Remove wire harness push in clip at bottom of coolant bracket. 9. Remove two cooler bracket to block bolts. 10. Remove cooler assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 8650 Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Carefully position the oil cooler assembly to the vehicle. 2. Install two nuts and one bolt. Tighten to 11 Nm (95 in. lbs.) torque. 3. Connect the quick-connect fittings to the transmission cooler lines. 4. Install Charge Air Cooler. 5. Start the engine and check all fittings for leaks. 6. Check the fluid level in the automatic transmission. Water-To-Oil Cooler INSTALLATION - WATER-TO-OIL COOLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 8651 1. Position oil cooler on cylinder block. 2. Install 2 capscrews to cylinder block finger tight. 3. Install capscrews at the transmission adapter. Torque bolt to 24 Nm (18 ft. lbs.) 4. Tighten lower mounting bolt to cooler at the cylinder block. Tighten to 77 Nm (57 ft. lbs.). NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Tighten upper mounting bolt to cooler at cylinder block to 24 N.m (18 ft. lbs). 6. Install wire harness push in clip at bottom of cooler bracket. 7. Install starter motor. 8. Connect battery negative cables. 9. Fill cooling system. 10. Check transmission oil level and fill as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 8652 Transmission Cooler: Service and Repair Transmission Oil Cooler Lines TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove dust cap by pulling it straight back off of quick connect fitting. 2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove. CONNECT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 8653 1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting. 2. Push in on transmission cooler line until a "click" is heard or felt. 3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step 2. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8658 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8659 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8660 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8661 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8662 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8663 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8664 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8665 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8666 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8667 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8668 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8671 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8672 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8673 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8674 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8675 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8676 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8677 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8678 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8679 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8680 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8681 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8684 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8685 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8686 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8687 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 8688 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8691 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8692 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8693 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8694 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8695 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8700 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8701 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8702 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8703 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8704 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8705 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8706 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8707 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8708 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8709 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8710 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8711 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8712 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8713 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8714 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8715 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8716 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8717 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8718 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8721 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8722 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8723 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8724 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8725 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8726 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8727 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8728 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8729 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8730 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8731 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8732 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8733 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8734 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8735 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8736 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8737 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8738 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8739 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION 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. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8742 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8743 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8746 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8747 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8748 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8749 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8753 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8754 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8755 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Valve Body: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components. By adjusting the spring pressure acting on the regulator valve, transmission line pressure can be adjusted. Upper Housing Control Valve Locations - Regulator valve (2) - Switch valve (3) - Regulator valve spring (4) - Kickdown valve (5) - Kickdown detent (6) - Throttle valve and spring (7) - Manual valve (8) - 1-2 Governor plug (9) - Throttle pressure plug (11) - 2-3 Governor plug (12) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8760 - Shuttle valve primary spring (13) Shuttle and Boost Valve Locations - Boost Valve (3) - Boost valve plug (4) - Shuttle valve (9) - Shuttle valve throttle plug (12) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8761 Upper Housing Shift Valve and Pressure Plug Locations - 1-2 shift valve (2) - 1-2 control valve - 2-3 shift valve - 2-3 throttle plug - Throttle pressure plug - Limit valve and spring Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8762 Lower Housing Shift Valves and Springs - 3-4 shift valve - 3-4 timing valve - 3-4 quick fill valve - 3-4 accumulator - Converter clutch lock-up valve - Converter clutch lock-up timing valve Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8763 CHECK BALLS REGULATOR VALVE Regulator Valve in Park Position The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid. The pressure regulator valve is located in the valve body near the manual valve. The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the left. This closes a dump (vent) that is used to lower pressure. The closing of the dump will cause the oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the right, opening the dump and lowering oil pressure. The result is spring pressure working against oil pressure to maintain the oil at specific pressures. With the engine running, fluid flows from the pump to the pressure regulator valve, manual valve, and the interconnected circuits. As fluid is sent through passages to the regulator valve, the pressure pushes the valve to the right against the large spring. It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug. With the gear selector in the PARK position, fluid recirculates through the regulator and manual valves back to the sump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8764 Regulator Valve in Neutral Position Meanwhile, the torque converter is filled slowly. In all other gear positions, fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter. After the torque converter and switch valve fill with fluid, the switch valve becomes the controlling metering device for torque converter pressure. The regulator valve then begins to control the line pressure for the other transmission circuits. The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land #2 (land #1 being at the far right of the valve in the diagram). As fluid leaks past the land, it moves into a groove connected to the filter or sump. As the land meters the fluid to the sump, it causes the pressure to reduce and the spring decreases the size of the metering passage. When the size of the metering passage is reduced, the pressure rises again and the size of the land is increased again. Pressure is regulated by this constant balance of hydraulic and spring pressure. Regulator Valve in Drive Position The metering at land #2 establishes the line pressure throughout the transmission. It is varied according to changes in throttle position and the transmission's internal condition within a range of 57-94 psi (except in REVERSE). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8765 Regulator Valve in Reverse Position The regulated line pressure in REVERSE is held at much higher pressures than in the other gear positions: 145-280 psi. The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land #4. With this pressure blocked, there is less area for pressure to act on to balance the force of the spring on the right. This allows line pressure to push the valve train to the right, reducing the amount of fluid returned to the pump's inlet, increasing line pressure. KICKDOWN VALVE Kickdown Valve - Wide Open Throttle When the throttle valve is as far over to the left as it can go, the maximum line pressure possible will enter the throttle pressure circuit. In this case, throttle pressure will equal line pressure. With the kickdown valve pushed into the bore as far as it will go, fluid initially flows through the annular Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8766 groove of the 2-3 shift valve (which will be in the direct drive position to the right). After passing the annular groove, the fluid is routed to the spring end of the 2-3 shift valve. Fluid pressure reacting on the area of land #1 overcomes governor pressure, downshifting the 2-3 shift valve into the kickdown, or second gear stage of operation. The valve is held in the kickdown position by throttle pressure routed from a seated check ball (#2). Again, if vehicle speed is low enough, throttle pressure will also push the 1-2 shift valve left to seat its governor plug, and downshift to drive breakaway. KICKDOWN LIMIT VALVE Kickdown Limit Valve - Low Speeds The purpose of the limit valve is to prevent a 3-2 downshift at higher speeds when a part-throttle downshift is not desirable. At these higher speeds only a full throttle 3-2 downshift will occur. At low road speeds the limit valve does not come into play and does not affect the downshifts. Kickdown Limit Valve - High Speeds As the vehicle's speed increases, the governor pressure also increases. The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore. This pushes the valve upward against the spring and bottoms the valve against the top of the housing. With the valve bottomed against the housing, the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve. When the supply of throttle pressure has been shut off, the 3-2 part throttle downshift plug becomes inoperative, because no pressure is acting on its reaction area. 1-2 SHIFT VALVE 1-2 Shift Valve - Before Shift Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8767 The 1-2 shift valve assembly, or mechanism, consists of: the 1-2 shift valve, governor plug, and a spring on the end of the valve. After the manual valve has been placed into a forward gear range, line pressure is directed to the 1-2 shift valve. As the throttle is depressed, throttle pressure is applied to the right side of the 1-2 shift valve assembly. With throttle pressure applied to the right side of the valve, there is now both spring pressure and throttle pressure acting on the valve, holding it against the governor plug. As the vehicle begins to move and build speed, governor pressure is created and is applied to the left of the valve at the governor plug. 1-2 Shift Valve - After Shift When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve, the valve will begin to move over to the right. As the valve moves to the right, the middle land of the valve will close off the circuit supplying the throttle pressure to the right side of the valve. When the throttle pressure is closed off, the valve will move even farther to the right, allowing line pressure to enter another circuit and energize the front servo, applying the front band. The governor plug serves a dual purpose: - It allows the shift valves to move either left or right, allowing both upshifts and downshifts. - When in a manual selection position, it will be hydraulically "blocked" into position so no upshift can occur. The physical blocking of the upshift while in the manual "1" position is accomplished by the directing of line pressure between both lands of the governor plug. The line pressure reacts against the larger land of the plug, pushing the plug back against the end plate overcoming governor pressure. With the combination of the line pressure and spring pressure, the valve cannot move, preventing any upshift. 1-2 SHIFT CONTROL VALVE 1-2 Shift Control Valve It contains a valve with four lands and a spring. It is used as both a "relay" and "balanced" valve. The valve has two specific operations: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8768 - Aid in quality of the 1-2 upshift. - Aid in the quality and timing of the 3-2 kickdown ranges. When the manual valve is set to the DRIVE position and the transmission is in the first or second gear range, 1-2 shift control or "modulated throttle pressure" is supplied to the middle of the accumulator piston by the 1-2 shift control valve. During the 1-2 upshift, this pressure is used to control the kickdown servo apply pressure that is needed to apply the kickdown and accumulator pistons. Thus, the 1-2 shift point is "cushioned" and the quality is improved. During a WOT kickdown, kickdown pressure is applied between the kickdown valve and the 1-2 shift control valve. This additional pressure is directed to the 1-2 shift control's spring cavity, adding to the spring load on the valve. The result of this increased "modulated" throttle pressure is a firmer WOT upshift. 2-3 SHIFT VALVE 2-3 Shift Valve - Before Shift The 2-3 shift valve mechanism consists of the 2-3 shift valve, governor plug and spring, and a throttle plug. After the 1-2 shift valve has completed its operation and applied the front band, line pressure is directed to the 2-3 shift valve through the connecting passages from the 1-2 shift valve. The line pressure will then dead-end at land #2 until the 2-3 valve is ready to make its shift. Now that the vehicle is in motion and under acceleration, there is throttle pressure being applied to the spring side of the valve and between lands #3 and #4. 2-3 Shift Valve - After Shift As vehicle speed increases, governor pressure increases proportionately, until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve. Since the throttle pressure end of the 2-3 shift valve is larger in diameter than the 1-2 shift valve, the 2-3 shift will always happen at a greater speed than the 1-2 shift. When this happens, the governor plug is forced against the shift valve moving it to the right. The shift valve causes land #4 to close the passage supplying throttle pressure to the 2-3 shift valve. Without throttle pressure present in the circuit now, the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8769 governor plug will push the valve over far enough to bottom the valve in its bore. This allows land #2 to direct line pressure to the front clutch. After the shift, line pressure is directed to the release side of the kickdown servo. This releases the front band and applies the front clutch, shifting into third gear or direct drive. The rear clutch remains applied, as it has been in the other gears. During a manual "1" or manual "2" gear selection, line pressure is sent between the two lands of the 2-3 governor plug. This line pressure at the governor plug locks the shift valve into the second gear position, preventing an upshift into direct drive. The theory for the blocking of the valve is the same as that of the 1-2 shift valve. If the manual "2" or manual "1" gear position is selected from the drive position, the PCM will control the timing of the downshift by targeting for a high governor pressure. When a safe vehicle speed is reached, the PCM will switch to its normal control governor curve and the downshift will occur. 3-4 SHIFT VALVE 3-4 Shift Valve Before Shift The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8770 3-4 Shift Valve After Shift Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. 3-4 TIMING VALVE 3-4 Shift Valve After Shift The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve or the converter clutch valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8771 3-4 Shift Valve Before Shift After the shift, the timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from downshifting while either the overdrive clutch or converter clutch is applied. 3-4 QUICK FILL VALVE 3-4 Shift Valve Before Shift The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8772 3-4 Shift Valve After Shift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. THROTTLE VALVE Throttle Valve In all gear positions, the throttle valve is being supplied with line pressure. The throttle valve meters and reduces the line pressure that now becomes throttle pressure. The throttle valve is moved by a spring and the kickdown valve, which is mechanically connected to the throttle. The larger the throttle opening, the higher the throttle pressure (to a maximum of line pressure). The smaller the throttle opening, the lower the throttle pressure (to a minimum of zero at idle). As engine speed increases, the increase in pump speed increases pump output. The increase in pressure and volume must be regulated to maintain the balance within the transmission. To do this, throttle pressure is routed to the reaction area on the right side of the throttle pressure plug (in the regulator valve). The higher engine speed and line pressure would open the vent too far and reduce line pressure too much. Throttle pressure, which increases with engine speed (throttle opening), is used to oppose the movement of the pressure valve to help control the metering passage at the vent. The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve. The larger spring at the right closes the regulator valve passage and maintains or increases line pressure. The increased line pressure works against the reaction area of the line pressure plug and the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8773 reaction area left of land #3 simultaneously moves the regulator valve train to the right and controls the metering passage. The kickdown valve, along with the throttle valve, serve to delay upshifts until the correct vehicle speed has been reached. It also controls downshifts upon driver demand, or increased engine load. If these valves were not in place, the shift points would be at the same speed for all throttle positions. The kickdown valve is actuated by a cam connected to the throttle. This is accomplished through either a linkage or a cable. The cam forces the kickdown valve toward the throttle valve compressing the spring between them and moving the throttle valve. As the throttle valve land starts to uncover its port, line pressure is "metered" out into the circuits and viewed as throttle pressure. This increased throttle pressure is metered out into the circuits it is applied to: the 1-2 and 2-3 shift valves. When the throttle pressure is high enough, a 3-2 downshift will occur. If the vehicle speed is low enough, a 2-1 downshift will occur. SWITCH VALVE Switch Valve - Torque Converter Unlocked When the transmission is in Drive Second before the TCC application occurs, the pressure regulator valve is supplying torque converter pressure to the switch valve. The switch valve directs this pressure through the transmission input shaft, into the converter, through the converter, back out between the input shaft and the reaction shaft, and back up to the switch valve. From the switch valve, the fluid pressure is directed to the transmission cooler, and lubrication pressure returns from the cooler to lubricate different portions of the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8774 Switch Valve - Torque Converter Locked MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the side of the valve body. The valve is connected mechanically by either a cable or linkage to the gearshift mechanism. The valve is held in each of its positions by a spring-loaded roller or ball that engages the "roostercomb" of the manual valve lever. Manual Valve Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8775 Once the TCC control valve has moved to the right, line pressure is directed to the tip of the switch valve, forcing the valve to the right. The switch valve now vents oil from the front of the piston in the torque converter, and supplies line pressure to the (rear) apply side of the torque converter piston. This pressure differential causes the piston to apply against the friction material, cutting off any further flow of line pressure oil. After the switch valve is shuttled right allowing line pressure to engage the TCC, torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits. CONVERTER CLUTCH LOCK-UP VALVE The torque converter clutch (TCC) lock-up valve controls the back (ON) side of the torque converter clutch. When the PCM energizes the TCC solenoid to engage the converter clutch piston, pressure is applied to the TCC lock-up valve which moves to the right and applies pressure to the torque converter clutch. CONVERTER CLUTCH LOCK-UP TIMING VALVE The torque converter clutch (TCC) lock-up timing valve is there to block any 4-3 downshift until the TCC is completely unlocked and the clutch is disengaged. SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves. When the manual valve is positioned in the Drive range, throttle pressure acts on the throttle plug of the shuttle valve to move it against a spring, increasing the spring force on the shuttle valve. During a part or full throttle 1-2 upshift, the throttle plug is bottomed by throttle pressure, holding the shuttle valve to the right against governor pressure, and opening a by-pass circuit. The shuttle valve controls the quality of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits. During a 3-2 kickdown, fluid discharges through the shuttle by-pass circuit. When the shuttle valve closes the by-pass circuit, fluid discharge is restricted and controlled for the application of the front band. During a 2-3 "lift foot" upshift, the shuttle valve by-passes the restriction to allow full fluid flow through the by-pass groove for a faster release of the band. BOOST VALVE Boost Valve Before Lock-up The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8776 Boost Valve After Lock-up The boost valve also serves to increase line pressure during torque converter lock-up. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8777 Valve Body: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION Valve Body Components The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components: - Solenoid switch valve - Manual valve - Low/reverse shuttle valve - 5 Accumulators Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8778 Check Ball Locations - 7 check balls Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In all other gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8779 Valve Body: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The valve body consists of a two piece aluminum valve body. Extensive electronic control effected by a microcomputer (the automatic transmission electronic control unit) over the hydraulic circuitry enables precise control over gearshifts. The valve body contains valves and pressure sensors that control fluid delivery to the torque converter clutch, forward clutches, and brake clutches. UPPER VALVE BODY UPPER VALVE BODY The upper valve body contains the following components: - 1 = Combined Drain - 2 = Gain change solenoid valve - 3 = Manual valve - 4 = Modulator valve - 5 = Shift solenoid valve No. 3 - 6 = Shift solenoid valve No. 2 - 7 = Shift valve No. 1 LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8780 LOWER VALVE BODY The lower valve body contains the following components: - 1 = Control valve No. 3 - 2 = Shift solenoid valve No. 4 - 3 = Lockup control valve - 4 = Control valve No. 1 - 5 = Control valve No. 2 SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8781 VALVE BODY OIL SWITCH HARNESS There are eight pressure switches and one ATF temperature switch used to inform the Transmission Control Module (TCM) when there is pressure in various hydraulic circuits. Six of them are located on the bottom of the valve body. The remainder are located on the top of the valve body. SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8782 VALVE BODY SOLENOID HARNESS Eight solenoids are used to control various shift functions in the transmission. Four are located on the top of the valve body (3, 4) and the remainder are located on the bottom of the valve body. Operation OPERATION LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8783 LOWER VALVE BODY UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8784 UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8785 SWITCHES AND SOLENOIDS VALVE BODY OIL SWITCH HARNESS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8786 SWITCHES AND SOLENOIDS VALVE BODY SOLENOID HARNESS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8787 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 8788 Valve Body: Adjustments ADJUSTMENTS - VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body; - Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT 1. Measure distance (2) from the valve body to the inner edge of the adjusting screw with an accurate steel scale. Distance should be 33.4 mm (1-5/16 in.). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 in.) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT 2. Insert Throttle Setting Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem (2). 3. Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. 4. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Valve Body: Service and Repair 68RFE Automatic Transmission Cleaning CLEANING Clean the valve housings, valves, plugs, springs, transfer plate and separator plate with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Inspection INSPECTION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8791 Valve Body Components NOTE: Only the INNER accumulator seal ring actually seals the pressure in the bore. The outer seal ring only serves to guide the piston in the bore. Gouges which do not extend past the inner seal ring (and have no raised edges, which could damage the guide ring) are acceptable. The machined accumulator bores often have a tiger-striped appearance. This is NORMAL and does NOT require replacement, as long as the bores are smooth in the inner seal ring area. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not normally change dimensionally with use. If the valve body functioned correctly when new, it should continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body as well as the accumulator piston seal rings, and replace if cut or damaged. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8792 Valve Body Seals Inspect all the fluid seals on the valve body. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8793 Valve Body: Service and Repair 48RE Automatic Transmission Cleaning CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Inspection INSPECTION Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8794 - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8795 Valve Body: Service and Repair AS68RC Automatic Transmission Cleaning CLEANING UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8796 LOWER VALVE BODY Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8797 SOLENOID FILTER SCREEN 1 - SOLENOID FILTER SCREEN Clean the solenoid filter screen (1), (if equipped). Inspection INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8798 SOLENOID FILTER SCREEN 1 - SOLENOID FILTER SCREEN Inspect all solenoid filter screens (1). Inspect all the fluid seals in the transmission case. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Adjustments Clutch Disc: Adjustments PRESSURE PLATE DIAPHRAGM SPRINGS NOTE:Perform the following procedure, when replacing only the clutch disc on Diesel vehicles with Dual Mass Flywheel and self- adjusting pressure plate. The pressure plate must be reset before installing a new disc. 1. Support pressure plate flange with press blocks (3) on a press. 2. Center press ram (2) on the pressure plate diaphragm spring fingers (1). 3. Compress the diaphragm spring fingers (1), until tension is released from the stepped adjusting ring. 4. Place two screwdrivers against two of the three stepped adjusting ring (1) tension spring stops, just ahead of the adjusting ring tension springs on the pressure plate (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Adjustments > Page 8803 5. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until the coil springs are fully compressed. Then hold adjusting ring while releasing the press pressure. 6. Remove the screwdrivers. The pressure plate is know adjusted for a new clutch disc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal Clutch Disc: Service and Repair Clutch Disc - Removal REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8806 Clutch Disc: Service and Repair Clutch Disc - Installation INSTALLATION CAUTION: Before installing a clutch disc on the Diesel engine with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Failure to reset the pressure will result in damage to the clutch disc. 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. NOTE: Over the wear life of a clutch disc the pressure plate will loose some of it's clamp load. It is recommended when replacing a worn clutch, the pressure plate is replaced at the same time. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: - V6 & V8 Engines - 50 Nm (37 ft. lbs.) - Diesel Engines - 30 Nm (22 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8807 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar(R) high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). 10. Apply light coat of Mopar(R) high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8808 12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4) and release bearing (3) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder and depress clutch pedal several time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8814 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Page 8815 Clutch Fluid: Specifications Chrysler does not provide a fluid type specification for the master/slave cylinder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal Clutch Master Cylinder: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal > Page 8820 Clutch Master Cylinder: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal Clutch Slave Cylinder: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal > Page 8825 Clutch Slave Cylinder: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Removal Hydraulic Hose: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Removal > Page 8830 Hydraulic Hose: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal Clutch Release Bearing: Service and Repair Removal REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal > Page 8838 Clutch Release Bearing: Service and Repair Installation INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal Clutch Release Fork: Service and Repair Removal REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal > Page 8843 Clutch Release Fork: Service and Repair Installation INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal Pilot Bearing: Service and Repair Removal REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove pressure plate (2) and clutch disc. 3. Remove pilot bearing with an internal puller and slide hammer to remove. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal > Page 8848 Pilot Bearing: Service and Repair Installation INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing (1) with clutch alignment tool (2) and letter side of the bearing (3) facing the transmission. Bearing should be flush with edge of bearing bore. CAUTION: Do not allow bearing to become cocked and do not recess bearing. 3. Install clutch disc, pressure plate and transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Align and hold pressure plate in position and install bolts finger tight. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. Pressure Plate Bolts - V6 & V8 Tighten to ........................................................................................... ....................................................................................................... 50 Nm (37 ft.lbs.) Pressure Plate Bolts - Diesel Tighten to ...................................................................................................................... ............................................................................ 30 Nm (22 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8858 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8863 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8870 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8871 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8876 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8877 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8878 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8879 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8880 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8883 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8884 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8885 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8886 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8887 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD Differential Cover: Service and Repair Front Axle - C205FD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove vent hose. 3. Remove differential cover (1) bolts (2). 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 4 mm (0.15 in.) bead of Mopar(R) Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover (2) and identification tag. Tighten cover bolts in a criss-cross pattern to 23 Nm (17 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD > Page 8892 Differential Cover: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 6.35mm (1/4 in.) bead of Mopar(R) Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential with lubricant to specifications. 4. Install fill plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8898 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8899 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8904 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8905 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8906 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8907 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8908 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8911 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8912 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8913 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8914 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8915 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8920 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle C205FD .............................................................................................................................. ....................................................................... 1.6 L ( 56 ounces) 9 1/4 AA ......................................... ............................................................................................................................................................ 2.2 L (74 ounces) 9 1/4 AA EL ............................................................................................................ ................................................................................... 2.0 L (68 ounces) Rear Axle 9 1/4 .................................................................................................................................... ....................................................................... 2.1 L (72 ounces) 10 1/2 AA ........................................ ........................................................................................................................................................... 2.5 L (85 ounces) 10 1/2 AA EL .......................................................................................................... ................................................................................... 2.5 L (85 ounces) 11 1/2 AA Open .................. .............................................................................................................................................................. ....... 4.2 L (142 ounces) 11 1/2 AA Trac-Rite ...................................................................................... .......................................................................................... 4.0 L (135 ounces) Note: With Track-Lok add 118 ml (4 oz) of Limited Slip Additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 8923 Fluid - Differential: Fluid Type Specifications Note: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. Front Axle c205FD - Mopar Gear Lubricant 75W-90 9 1/4 AA - Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL - Mopar Synthetic Gear Lubricant 75W-90 Rear Axle 9 1/4 - Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA - Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL - Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA - Mopar Synthetic Gear Lubricant 75W-90 Note: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differential DO NOT require Limited Slip Additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal Differential Output Shaft Bearing: Service and Repair Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove disconnect actuator wiring connector. 3. Remove disconnect actuator (1) bolts (2) and remove actuator from disconnect pocket. 4. Remove O-ring (1) and snap ring (2) from output shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8929 5. Remove disconnect seal (1) bolts (2). 6. Remove output shaft (1) and disconnect seal (2) with Remover 8420A (3) and Slide Hammer C-3752. 7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8930 8. Remove differential cover. 9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2). 10. Remove intermediate shaft (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8931 11. Install Puller 9766 (1) in intermediate shaft bearing (2) then tighten nut (3) to expand tool in bearing. 12. Tighten puller (1) nut (2) to remove intermediate shaft bearing from disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8932 Differential Output Shaft Bearing: Service and Repair Installation INSTALLATION 1. Install intermediate shaft bearing (1) with Installer 9767 (2) and Handle C-4171. CAUTION: Bearing must be installed with lettering facing outwards. Failure to follow these instructions will damage the bearing. 2. Install new intermediate shaft snap ring. 3. Install intermediate shaft (1) through disconnect pocket (2) and verify intermediate shaft snap ring is seated in side gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8933 4. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2). 5. Position disconnect collar (1) on intermediate shaft (2) in 2WD position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8934 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD Seals and Gaskets: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove O-ring (1) and snap ring (2) from the output shaft. 3. Remove disconnect seal (1) bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8939 4. Remove output shaft and disconnect seal (1) with Remover 8420A (2) and Slide Hammer C-3752. Installation INSTALLATION 1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8940 2. Install output shaft (1) in disconnect pocket (2). 3. Install disconnect seal (1) on output shaft (2). 4. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8941 5. Install disconnect seal (1) in disconnect pocket with Installer 6761(2) and a hammer. 6. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 7. Install output shaft O-ring (1) and snap ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8942 8. Install half shaft. 9. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8943 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install O-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8944 1. With axle in 2WD remove front propeller shaft and left half shaft. 2. Rotate pinion gear three or four times and verify pinion rotates smoothly. 3. Record pinion torque to rotate with an inch pound torque wrench (2), for installation reference. 4. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. 5. Remove pinion nut. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a seal puller. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8945 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. 5. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange. 6. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the axle. 7. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). 8. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instruction will damage the axle. 9. Install propeller shaft and half shafts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8946 Seals and Gaskets: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8947 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8948 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. 5. Install axle shaft and hub bearings. Removal REMOVAL 1. Mark propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Record pinion torque to rotate (1) with an inch pound torque wrench (2) for installation reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8949 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 7. Mark a line across the pinion shaft and flange for installation reference. 8. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 9. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8950 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap pinion flange onto the pinion, until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (1) with Flange Wrench 8979 (2) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion flange (1) several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts and hub bearings. 12. Install propeller shaft with reference marks aligned. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8951 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8952 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. 4. Rotate companion flange three or four times. 5. Record pinion torque to rotating (1) with an inch pound torque wrench (2). 6. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 7. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 8. Mark a line across the pinion shaft and flange for installation reference. 9. Remove companion flange with Puller C-452 (2). 10. Remove pinion seal with seal puller or slide-hammer mounted screw. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8953 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal (3) with Handle C-4735 and Installer C-4076-B (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719A. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. 8. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.). NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8954 9. Rotate pinion several times to ensure pinion bearings are seated. 10. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle. 11. Install propeller shaft. 12. Install rear brake rotors components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8955 Seals and Gaskets: Service and Repair Rear Axle - 10 1/2 AA Removal REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Record pinion torque to rotate (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Wrench 8979 (2) and remove pinion flange nut and washer. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove pinion flange (1) with Puller 8992 (2). 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8956 Installation INSTALLATION 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap the pinion flange onto the pinion until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts. 12. Install propeller shaft with reference marks aligned. 13. Check and fill differential if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8957 Seals and Gaskets: Service and Repair Rear Axle - 11 1/2 AA Removal REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 8. Remove pinion shaft seal with a seal puller or slide hammer mounted screw. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8958 Installation INSTALLATION 1. Install new pinion seal with Handle C-4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40-0.57 Nm (3-5 in. lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion Torque To Rotate again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD Axle Bearing: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2) (3) Collar 8420-3 (4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. 6. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread remover in the bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8964 7. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw the bearing out. Installation INSTALLATION 1. Wipe axle shaft bearing bore clean. 2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2). CAUTION: Bearing must be installer with lettering facing outwards. Failure to follow these instructions will damage the bearing. 3. Install a new axle shaft seal with Installer 8694 (1). 4. Lubricate seal lip with gear lubricant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8965 5. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 6. Install axle shaft (3) O-ring (1) and snap ring (2). 7. Install half shaft. 8. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8966 Axle Bearing: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 6310-9 (7). Installation INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8967 Axle Bearing: Service and Repair Rear Axle - 10 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from axle shaft tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8968 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8969 Axle Bearing: Service and Repair Rear Axle - 11 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) form axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8970 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with a pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. Installation INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C-4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten with torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025-0.25 mm (0.01-0.001 in.) 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures Axle Shaft: Procedures Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure axle to lift. 3. Remove all brake components. 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8976 1. Raise axle with lift and align to the leaf spring centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8977 NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar(R) Lock N' Seal or Loctite(R) 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar(R) Lock N' Seal or Loctite(R) 242 on cleaned existing bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8978 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm ( 95 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8979 Axle Shaft: Removal and Replacement Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8980 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 3. Install O-ring (1) and snap ring (2) on axle shaft (3). 4. Install half shaft. 5. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped. 3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8981 4. Remove four hub bearing bolts (2) from the back of the steering knuckle. 5. Remove hub bearing from the steering knuckle. 6. Remove axle shaft (2) from steering knuckle (1) and axle housing. Installation INSTALLATION 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (2) through the steering knuckle (3) and into the differential side gears. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8982 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (2) and tighten to 202 Nm (149 ft. lbs.). 5. Install ABS wheel speed sensor, brake rotor and caliper. 6. Install axle (2) washer and nut (1). Tighten axle nut to 179 Nm (132 ft. lbs.). 7. Rotate axle several 5 to 10 times to seat the wheel bearing. 8. Tighten axle nut (1) to final torque of 356 Nm (263 ft. lbs.). 9. Align nut to next cotter pin hole and install new cotter pin (3). Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8983 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION 1. Raise axle with lift and align to the leaf spring centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8984 1. Remove lubricant fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant from housing. 3. Remove axle shafts. 4. Remove adjuster lock bolts (1) and adjuster locks (2). 5. Mark bearing caps (4) left and right for installation reference. 6. Remove bearing cap bolts and remove bearing caps. 7. Loosen differential bearing (1, 3) adjusters (2, 4) with a hammer and punch. 8. Remove differential case from the housing. 9. Remove bearing cups (1, 3) and tag them left and right for installation reference. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8985 1. Clean housing (1) cavity with a flushing oil, light engine oil or lint free cloth. CAUTION: Do not use water, steam, kerosene or gasoline for cleaning. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. NOTE: A light coat of grease on the cups will hold them in place during installation. 4. Install bearing caps (2) and bolts. Tighten bearing cap bolts finger-tight. 5. Slide differential case (2) toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 6. Holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A (1) until they make contact with the differential bearings/cups. 7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 9. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 10. Rotate the pinion several times to seat the differential bearings. 11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 13. Tighten pinion gear side adjuster an additional: - New Bearings 6 Adjuster Holes - Original Bearings 4 Adjuster Holes 14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8986 15. Tighten bearing cap bolts to 165 Nm (122 ft. lbs.). 16. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.). 17. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 18. Install axle shafts. 19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 20. Fill differential with lubricant to specifications. 21. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL 1. Remove differential case from the housing. 2. Install Plug 8888 (4) into the end of the case. 3. Remove differential case bearings (3) with Bearing Splitter 1130 (2) and Bridge 938 (1). Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8987 1. Install open and Trac-Rite differential case (2) bearings (3) with Installer 8956 (4) and Handle C-4171 (1). 2. Install differential case into housing. Removal REMOVAL 1. Remove the differential case from the housing. 2. Install Plug 8888 (1) into the end of the differential case on the coil side. 3. Install Puller 6444 (2) onto the end of the plug (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8988 4. Install puller Jaws 9915 (1) onto puller (2) and around the bearing. 5. Install puller collar (1) onto puller jaws (2). Tighten puller bolt and remove bearing. NOTE: Bearing on the other side of the case can be removed with Puller C-293-PA and Adapters 9614. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8989 1. Install differential bearings (1) with Handle C-4171 (2) and Installer 8956 (3). Removal REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear. 1. Mark pinion flange and propeller shaft for installation alignment. 2. Disconnect propeller shaft from pinion flange and remove propeller shaft. 3. Remove differential from axle housing. 4. Place differential on Plug 8888 and drive exciter ring (4) off the differential case (1) with a hammer and punch (3). NOTE: Do not remove the exciter ring if it is not being replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8990 5. Place differential case in a vise with soft metal jaw protectors. 6. Remove bolts holding ring gear to differential case. 7. Drive ring gear (2) from differential case (1) with a soft hammer (3). 8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 9. Remove pinion flange (1) from the pinion with Flange Puller 8992 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8991 10. Remove pinion gear (1) from housing, with Pinion Driver 8977 (2) and a hammer. NOTE: Thread the driver on the pinion shaft till it bottoms out. 11. Remove pinion seal with a slide hammer or pry bar. 12. Remove and discard front pinion bearing. CAUTION: Do not reuse front pinion bearing/cup. 13. Remove collapsible spacer from the pinion shaft. 14. Remove rear pinion bearing with Puller C-293-PA (1) and Adapter Blocks 8879 (4). 15. Remove pinion depth shim from pinion gear shaft and record shim thickness. 16. Remove front pinion bearing cup from the housing with a punch and hammer and discard cup. CAUTION: Do not reuse front pinion bearing/cup. 17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8992 1. Install new front pinion bearing cup with Installer 8960 (1) and Handle C-4171 (2). 2. Install new rear pinion bearing cup with Installer 8959 (1) and Handle C-4171 (2). 3. Install pinion depth shim (1) on the pinion gear shaft (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8993 4. Install rear pinion bearing (4) on pinion (3) with Installer MD-998805 (2) and a press (1). 5. Install new collapsible spacer (1) on pinion gear (2). 6. Lubricate pinion and bearings. 7. Install pinion into housing (2) and place front pinion bearing onto the pinion shaft. Draw pinion shaft into the front bearing with Installer 8981 (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8994 8. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 9. Apply a light coat of teflon sealant to the pinion flange splines. 10. Hold the pinion and lightly tap the pinion flange onto the pinion, until a few threads are showing. 11. Install pinion flange washer and new pinion nut. 12. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 13. Rotate pinion several times to seat pinion bearings. 14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Pinion Torque To Rotate is: - New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.) - Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 in. lbs.) 15. Rotate pinion several times then verify pinion torque to rotate again. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8995 16. Position ring gear (2) on differential case (4) and start two new ring gear bolts. 17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear. 18. Torque ring gear bolts to 237 Nm (175 ft. lbs.). 19. If exciter ring was removed, position differential assembly on differential Plug 8888 and place exciter ring on the differential case. 20. Install exciter ring (1) on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (3). CAUTION: Do not damage exciter ring teeth during installation. 21. Install differential into the housing. 22. Verify ring gear backlash and gear contact pattern. 23. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is: - New Bearings: 3.4 - 5.6 Nm (30 - 50 in. lbs.) - Original Bearings: 2.8 - 5.1 Nm (25 - 45 in. lbs.) If TTTR is to high back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low tighten adjusters evenly on both sides slightly and check TTTR again. 24. Install axle shafts. 25. Install the propeller shaft with the reference marks aligned. 26. Install differential cover with gasket and tighten bolts to 40 Nm (30 ft. lbs.). 27. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8996 1. Remove lubricant fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant from housing. 3. Remove axle shafts. 4. Cut sensor wire tie strap (4) from adjuster lock. 5. Remove sensor target magnet (1) from bearing cap. 6. Remove adjuster lock bolts (3) and adjuster locks (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8997 7. Remove electric locker connector (1) retainer (2) bolt from differential housing. 8. Remove connector (1) and retainer (2) from differential housing. 9. Remove retainer (1) from connector and remove O-ring (2) from connector. 10. Mark bearing caps (2) left and right for installation reference. 11. Remove bearing cap bolts and remove bearing caps (2). 12. Loosen differential bearing adjusters (3) with a hammer and punch. 13. Slid electric locker connector through differential housing. 14. Remove differential case with bearing cups from the housing. 15. Tag bearing cups left and right for installation reference. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8998 1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. 4. Slide electric locker connector through differential housing. 5. Install O-ring (2) on electric locker connector. 6. Install electric locker connector retainer (1) and install connector with retainer in differential housing. 7. Install connector retainer bolt. 8. Install bearing caps (2) and tighten bearing cap bolts finger-tight. NOTE: Do not torque bearing cap and bolts at this time. 9. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 10. Holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A until they make contact with the differential bearings/cups. 11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 13. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 14. Rotate the pinion several times to seat the differential bearings. 15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 17. Tighten pinion gear side adjuster an additional: - New Bearings: 6 Adjuster Holes - Original Bearings: 4 Adjuster Holes 18. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 8999 19. Tighten bearing cap bolts (4) to 165 Nm (122 ft. lbs.). 20. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.). 21. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 22. Install axle shafts. 23. Install sensor target magnet (1) on bearing cap. 24. Energize locker and rotate axle shaft. Verify dog clutch is engaged by rotating one axle while holding the other. If engaged axle will not rotate. 25. De-energize locker and rotate left axle 15 to 40 degrees so dog clutch gears will not engage. 26. Energize locker and set sensor air gap (2) to 5.5 mm ± 0.25 mm (0.21 in. ± 0.01 in.). NOTE: System will time out within 2 minutes, when the key is in the on position and the engine is not running. 27. Tighten sensor target magnet bolt (3) to 7 Nm (62 in. lbs.). 28. Hold right axle and rotate left axle until dog clutch engages with an audible click nose. NOTE: This will verify the sensor air gap was adjusted with the dog clutch gears ear to ear. 29. Install sensor wire tie strap (4) in the original location or at white dot on wiring harness to the top leg of adjuster lock and de-energize coil. 30. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 31. Fill differential with lubricant to specifications. 32. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9000 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Mark propeller shaft and companion flange for installation alignment reference. 5. Remove propeller shaft. 6. Remove axle vent hose. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (4) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9001 1. Raise axle with lift and align to the leaf spring (1) centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install propeller shaft with reference marks aligned and tighten to specification. 6. Install axle vent hose. 7. Fill differential to specifications. 8. Remove lift from axle and lower the vehicle. Removal REMOVAL 1. Remove fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant. 3. Remove axle shafts. 4. Remove adjuster (3) lock bolts (1) and adjuster locks (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9002 5. Mark bearing caps left and right for installation reference. 6. Remove bearing cap bolts and remove bearing caps. 7. Loosen differential bearing (1, 3) adjusters (2, 4) with a hammer and punch. 8. Remove differential case from the housing. 9. Remove bearing cups (1, 3) and tag them left and right for installation reference. Installation INSTALLATION 1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. NOTE: Do not use water, steam, kerosene or gasoline for cleaning. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. NOTE: A light coat of grease on the cups will hold them in place during installation. 4. Install bearing caps (2) and bolts. Tighten the bearing cap (2) bolts finger-tight. NOTE: Do not torque bearing cap and bolts at this time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9003 5. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 6. Holding the differential case (2) toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A (1) until they make contact with the differential bearings/cups. 7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 9. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 10. Rotate the pinion several times to seat the differential bearings. 11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 13. Tighten pinion gear side adjuster an additional: - New Bearings 6 Adjuster Holes - Original Bearings 4 Adjuster Holes 14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 15. Tighten bearing cap bolts (4) to 281 Nm (207 ft. lbs.). 16. Tighten adjuster lock bolts (3) to 25 Nm (18 ft. lbs.). 17. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 18. Install axle shaft gasket and install axle shafts. 19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 20. Fill differential with lubricant to specifications. 21. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9004 1. Remove differential case from the housing. 2. Install Plug 8964 (4) into the end of the case. 3. Remove differential case bearings (3) with Bearing Splitter 1130 (2) and Bridge 938 (1). Installation INSTALLATION WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury. CAUTION: A bearing heater (2) is used to install Trac-Rite differential case bearings (1). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212° - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and extended amount of time. If component is discolored after heating the component has been overheated and must not be used. Failure to follow these instructions will result in component damage. 1. Heat Trac-Rite(R) differential case bearings (1) with bearing heater (2). 2. With welding gloves or tongs install bearings on differential case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9005 3. Install open differential case (2) bearings (3) with Installer 8965 (4) and Handle C-4171 (1). 4. Install differential case into housing. Removal REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear. 1. Mark pinion flange and propeller shaft for installation alignment. 2. Remove propeller shaft. 3. Remove differential from the housing. 4. Place differential case (1) on Plug 8964. Drive exciter ring (4) off the differential case with a hammer and punch (3). NOTE: Do not remove the exciter ring if it is not being replaced. 5. Place differential case in a vise with soft metal jaw protectors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9006 6. Remove bolts holding ring gear to differential case. 7. Drive ring gear (2) from differential case (1) with a soft hammer (3). 8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 9. Remove pinion flange (1) from pinion with pinion Puller 8992 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9007 10. Remove pinion gear (1) from housing with pinion Driver 8977 (2) and a hammer. NOTE: Thread the driver on the pinion shaft till it bottoms out. 11. Remove pinion seal with a slide hammer or pry bar. 12. Remove front pinion bearing and discard bearing. NOTE: Do not reuse front pinion bearing/cup. 13. Remove collapsible spacer from the pinion shaft. 14. Remove rear pinion bearing (1) with Bearing Splitter 1130 (2) and a press. 15. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims. 16. Remove front pinion bearing cup from the housing with a punch and hammer, and discard cup. NOTE: Do not reuse front pinion bearing/cup. 17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced. Installation INSTALLATION 1. Install new front pinion bearing cup with Installer 8960 (1) and Handle C-4171 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9008 2. Install new rear pinion bearing cup with Installer 8968 (1) and Handle C-4171 (2). 3. Install pinion depth shim (1) on the pinion gear shaft (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9009 4. Install rear pinion bearing (4) with Installer D-389 (1) and a press (1). 5. Install new collapsible spacer (1) on the pinion (2). 6. Lubricate pinion and bearings. 7. Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9010 8. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 9. Apply a light coat of teflon sealant to the pinion flange splines. 10. Hold pinion and lightly tap the pinion flange (2) onto the pinion, until a few threads are showing. 11. Install pinion flange washer and new pinion nut. 12. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is eliminated. 13. Rotate pinion several times to seat pinion bearings. 14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Pinion Torque To Rotate is: - New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.) - Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 in. lbs.) 15. Rotate pinion several times then verify pinion rotating torque again. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9011 16. Position the ring gear (2) on differential case (4) and start two new ring gear bolts. 17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear. 18. Torque ring gear bolts to 237 Nm (175 ft. lbs.). 19. If exciter ring was removed, position differential assembly on differential Plug 8965 and place exciter ring (1) on the differential case. 20. Install the exciter ring on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (2). 21. Install differential in housing and verify gear backlash and gear contact pattern. 22. Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is: - New Bearings: 3.4 - 5.6 Nm (30 - 50 in. lbs.) - Original Bearings: 2.8 - 5.1 Nm (25 - 45 in. lbs.) If TTTR is to high, back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low, tighten adjusters evenly on both sides slightly and check TTTR again. 23. Install axle shafts. 24. Install the propeller shaft with the reference marks aligned. 25. Install differential cover with gasket and tighten bolts to 40 Nm (30 ft. lbs.). 26. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer Constant Velocity Joint: Service and Repair CV Joint-Outer Removal REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. CAUTION: Do not damage C/V housing or half shaft. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring (1). 5. Spread snap ring (1) and slide the joint off the shaft. 6. Slide boot off the shaft and discard old boot. 7. Mark alignment marks (1) on the inner race/hub (2), bearing cage (3) and housing with dabs of paint. 8. Clamp C/V joint in a vertical position in a soft jawed vise. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9016 9. Press down one side of the bearing cage (3) to gain access to the ball at the opposite side. NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. 10. Remove ball (4) from the bearing cage (3). 11. Repeat step above until all six balls are removed from the bearing cage. 12. Lift cage and inner race (2) upward and out from the housing (1). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9017 NOTE: If C/V joint is worn, replace entire C/V joint and boot. 1. Clean all C/V joint components and shaft. 2. Apply a light coat of grease supplied with the joint/boot to the C/V joint components before assembling them. 3. Align the inner race (1) cage (2) and housing according to the alignment reference marks. 4. Insert the inner race (1) into the cage (2) and rotate race into the cage. 5. Rotate the inner race/hub (2) in the cage. 6. Insert cage (2) into the housing. Rotate the cage 90° into the housing (3) so the large bearing hub counterbore is facing outwards. 7. Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9018 8. Tilt inner race/hub (1) and cage (3) and install the balls(4). 9. Place new clamps onto new boot and slide boot onto the shaft to it's original position. 10. Apply the rest of grease to the C/V joint and boot. 11. Install the joint onto the shaft (2). Push the joint onto the shaft until the snap ring (1) seats in the groove (3). NOTE: Pull on the joint to verify the span ring has engaged. 12. Position the boot on the joint in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 13. Secure both boot (5) clamps (2) (4) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9019 Constant Velocity Joint: Service and Repair CV Joint-Inner Removal REMOVAL 1. Clamp shaft in vise (with soft jaws) and support C/V joint. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder. 3. Remove housing (2) from the half shaft and slide boot (1) down shaft. 4. Remove housing bushing from the housing. 5. Remove tripod (2) snap ring (1). 6. Remove tripod (2) and boot from the half shaft. 7. Clean and inspect C/V components for excessive wear and damage. Replace the tripod as a unit only if necessary. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9020 INSTALLATION 1. Clean all C/V joint components and shaft. 2. Slide new boot (1) down the half shaft. 3. Install tripod (2) and tripod snap ring on the half shaft. 4. Pack grease supplied with the joint/boot into the housing and boot. 5. Coat tripod with supplied grease. 6. Install new bushing (1) onto the housing (2). 7. Insert the tripod and shaft in the housing. 8. Position the boot (2) on the housing (5) and shaft (4) in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 9. Measure the distance from the end of the housing to the end of the boot on the shaft. This measurement should be 260 mm (10.25 in.). NOTE: If measurement is not correct, allow more or less air into the boot. 10. Secure both boot clamps (1) (3) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal Universal Joint: Service and Repair Removal REMOVAL NOTE: Saturate bearing caps with penetrating oil prior to removal. 1. Remove axle shaft. 2. Remove bearing cap snap rings (1) from stub shaft yoke (2) bearing caps. 3. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9025 4. Remove bearing cap (1) from stub shaft yoke (2). 5. Position receiver/socket (2) under stub shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 6. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9026 7. Remove snap rings (1) from shaft yoke (2) bearing caps. 8. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into receiver/socket (2). 9. Remove bearing cap (1) from shaft yoke (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9027 10. Position receiver/socket (2) under shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 11. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9028 Universal Joint: Service and Repair Installation INSTALLATION CAUTION: Keep cross and bearing cap straight during installation. Failure to follow these instruction will result in damage. 1. Pack bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base lubricant to aid in installation. 2. Position cross (1) in the shaft yoke (2). 3. Tap bearing cap into the yoke bores far enough to position cross. 4. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9029 5. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 6. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. 7. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9030 8. Install stub shaft yoke (1) on U-joint cross (2). 9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross. 10. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9031 11. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press. 13. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 14. Install axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD Seals and Gaskets: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9036 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install O-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9037 Seals and Gaskets: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9038 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9039 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. 5. Install axle shaft and hub bearings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9040 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9045 9. Remove the support and lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9046 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9047 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments Center Support: Adjustments BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 in.) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal Center Support: Service and Repair Removal REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference marks on rear shaft (1) and front shaft (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9058 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (1) between propeller shaft and center bearing (2). 6. Install Bridge 938 (3) on the splitter (1) and remove center bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9059 Center Support: Service and Repair Installation INSTALLATION 1. Slide center bearing (1) and boot collar (2) on shaft. 2. Install boot collar (2) and center bearing (1) with Installer 6448A. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9060 5. Slide slip yoke boot (1) on boot collar (2). 6. Install slip yoke boot (1) clamp (2). 7. Install propeller shaft in vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications PROPELLER SHAFT Torque Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9064 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also be caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. Driveline Vibration PROPELLER SHAFT BALANCE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9065 If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180 degrees relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90 degrees apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9066 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle Drive/Propeller Shaft: Service and Repair Propeller Shaft Angle PROPELLER SHAFT ANGLE ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a C/V joint, place inclinometer on machined surface of the C/V joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9069 This measurement will give you the Propeller Shaft Angle (C). 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example for additional information. RULES - Good cancellation of U-joint operating angles should be within 1 degree. - Operating angles should be less than 3 degrees. - Operating angles less than 10 degrees for double cardan U-joint. - At least 1/2 of one degree continuous operating propeller shaft angle. TWO PIECE PROPELLER SHAFT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9070 Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9071 Drive/Propeller Shaft: Service and Repair Lubrication LUBRICATION Vehicles with double cardan universal joint front propeller shaft (1) are equipped with a grease fitting (2). Grease the double cardan universal joint at each oil change. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9072 Drive/Propeller Shaft: Service and Repair Propeller Shaft Front HD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across axle (3)/transfer case (2) companion flange and propeller shaft flange yokes for installation reference. 4. Remove axle/transfer case companion flange bolts. 5. Remove propeller shaft. Installation INSTALLATION 1. Install propeller shaft (1) with all reference marks aligned. 2. Install transfer case companion flange (2) bolts and tighten to 88 Nm (65 ft. lbs.). 3. Install new axle companion flange (3) bolts and tighten to 28 Nm (21 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite(R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite(R) 242 to the threads. 4. Install skid plate, if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9073 Drive/Propeller Shaft: Service and Repair Propeller Shaft Rear HD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3). 3. If equipped with manual transmission, mark manual transmission flange (1) and propeller shaft flange (2) for installation reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9074 4. If equipped with a center bearing (1) mark an outline of the center bearing on the center bearing bracket for installation reference. Then support propeller shaft and remove center bearing bolts (2). 5. Remove pinion flange (1) bolts from propeller shaft (2). 6. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9075 7. If equipped with manual transmission remove flange (1) bolts (2). 8. Remove propeller shaft from vehicle. CAUTION: Failure to follow these instructions may result in a driveline vibration. Installation INSTALLATION 1. Slide slip yoke (1) onto automatic transmission/transfer case output shaft (2) with reference marks aligned. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9076 2. If equipped with manual transmission, align transmission flange (1) and propeller shaft reference marks. Install new flange bolts (2) and tighten to 115 Nm (85 ft. lbs.). 3. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to 54 Nm (40 ft. lbs.). 4. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to 115 Nm (85 ft. lbs.) CAUTION: Failure to follow these instruction may result in a driveline vibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 9077 Drive/Propeller Shaft: Tools and Equipment PROPELLER SHAFT SPLITTER 1130 INSTALLER 6052 INSTALLER 6448A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 9078 INCLINOMETER 7663 BRIDGE 938 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan Universal Joint: Service and Repair Universal Joints-Single Cardan Disassembly - With Injected Ring DISASSEMBLY - WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9083 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-joint out of shaft yoke (2). 8. Position U-joint press (2) with receiver (1) on flange. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9084 9. Press U-joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-joint press (2) with receiver (1) on flange. 12. Press remaining U-joint bearing cap out of flange. 13. Remove U-joint from flange. Disassembly - With Snap Rings DISASSEMBLY - WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9085 3. Position yoke with the grease fitting if equipped, pointing up. 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If bearing cap will not pull out of the yoke after pressing, tap yoke ear near bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. Assembly - With Injected Ring ASSEMBLY - WITH INJECTED RING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9086 NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9087 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-joint in yoke (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9088 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9089 14. Install snap ring (2) on bearing cap (1). Assembly - With Snap Rings ASSEMBLY - WITH SNAP RINGS 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke (2) with lube fitting pointing up, if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9090 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat STEP 3 and STEP 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9091 Universal Joint: Service and Repair Universal Joints-Double Cardan Disassembly DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9092 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat STEP 6, STEP 7, STEP 8 and STEP 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. Assembly ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9093 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Fit cross into the propeller shaft yoke. 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9094 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9095 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Description and Operation Flywheel: Description and Operation DESCRIPTION STANDARD FLYWHEEL The standard (3) is a heavy plate bolted to the rear of the crankshaft (1). The flywheel incorporates the ring gear (2) around the outer circumference to mesh with the starter to permit engine cranking. The rear face of the flywheel serves as the driving member to the clutch disc. DUAL MASS FLYWHEEL The Dual Mass Flywheel (1) is used on the Diesel engine with G56 transmission. The flywheel incorporates the ring gear around the outer circumference to mesh with the starter to permit engine cranking. The primary flywheel side is bolted to an adapter plate which is bolted to the crankshaft. The secondary flywheel side (2) serves as the driving member to the clutch disc. Internal springs (3) are used to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and should never be taken apart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Description and Operation > Page 9099 Flywheel: Testing and Inspection FLYWHEEL Check flywheel (3) runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are: - heat warpage - improper machining - incorrect bolt tightening - improper seating on crankshaft flange shoulder - foreign material on crankshaft flange Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.). Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar(R) Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout. On a Dual Mass Flywheel (1) inspect all springs (2) for damage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal Flywheel: Service and Repair Removal REMOVAL 1. Remove the transmission. NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the flywheel and crank. This plate does not need to be removed. 2. Remove the dust cover bolts (1) and the dust cover (2). 3. Using the access hole, remove each flexplate-to-flywheel bolt (1). Use Barring Tool 7471B to rotate the engine and flywheel. 4. Remove the assembly place the flywheel (1) , clutch disc (2) , and pressure plate (3) assembly on a workbench. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 9102 5. Loosen pressure plate bolts (1-8) evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove the eight pressure plate bolts (1-8) completely and remove pressure plate and disc. 7. Remove the flywheel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 9103 Flywheel: Service and Repair Installation INSTALLATION 1. Install flywheel on the crankshaft or adapter plate if vehicle has Dual Mass flywheel. 2. Install flywheel bolts and tighten evenly in sequence to 95 Nm (70 ft. lbs.). Vehicles with Dual Mass Flywheel, tighten adapter plate bolts to 55 Nm (40 ft. lbs.). 3. Install clutch. 4. Install transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9110 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9111 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9112 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 9117 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9123 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9124 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9125 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 9130 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9137 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9142 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications G56 ...................................................................................................................................................... .......................................................... 5.6 L (12 pints) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 9145 Fluid - M/T: Fluid Type Specifications Mopar ATF +4 Transmission Fluid Note: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 9155 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 9161 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9172 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9173 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9178 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9179 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9180 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9181 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9187 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9188 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9193 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9194 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9195 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9196 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9197 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9198 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9199 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9200 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9201 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9202 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9203 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9204 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9205 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9206 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9209 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9210 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9211 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9212 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9213 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9214 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9215 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL 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. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. 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 the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9220 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9221 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9225 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9226 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9227 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 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 (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9231 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9232 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 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. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9235 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9237 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 area. 6. Verify the 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 L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9238 Transmission Control System Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9245 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9246 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9247 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9248 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9249 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9252 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9253 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9254 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9255 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9261 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9262 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9263 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 9266 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 9269 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9273 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9274 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9275 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9276 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9279 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9280 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9281 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9282 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9283 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9284 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9285 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9290 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9291 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9292 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9293 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9294 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9295 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9296 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9297 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9298 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9299 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9300 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9303 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9304 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9305 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9306 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9307 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9308 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9309 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9310 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9311 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9312 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9313 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9316 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9317 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9318 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9319 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 9320 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9323 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9324 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9325 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9326 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9327 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9332 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9333 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9334 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9335 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9336 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9337 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9338 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9339 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9340 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9341 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9342 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9343 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9344 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9345 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9346 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9347 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9348 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9349 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9350 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9353 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9354 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9355 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9356 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9357 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9358 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9359 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9360 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9361 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9362 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9363 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9364 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9365 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9366 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9367 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9368 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9369 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9370 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9371 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION 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. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9374 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9375 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9378 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9379 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9380 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9381 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9385 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9386 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9387 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 9397 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9402 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9403 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9404 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9405 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9406 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9407 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9408 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9411 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9412 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9413 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9414 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9415 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9416 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9417 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9422 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9423 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9424 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9425 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9426 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9427 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9428 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9429 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9430 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9433 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9434 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9435 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9436 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9437 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9438 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9439 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9440 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9441 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9444 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9445 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9446 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9447 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9448 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9449 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9450 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9451 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9452 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 9455 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9460 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9461 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9462 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 9465 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 9466 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 9467 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 9470 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9476 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9477 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9478 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9479 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9480 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9481 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9482 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9483 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9484 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9485 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9486 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9487 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 9488 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 9491 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 9492 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 9493 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 9494 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9497 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9498 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9499 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9500 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9501 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 9502 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9506 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9507 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9508 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9509 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 9510 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9513 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9514 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9515 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9516 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9522 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9527 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV241 GEN II ...................................................................................................................................... ....................................................... 1.6 L 3.4 (pints) NV243 ................................................................ .......................................................................................................................................... 1.6 L (3.4 Pints) NV244 GEN II ............................................................................................................................ ................................................................. 1.6 L (3.4 pints) NV246 ...................................................... .................................................................................................................................................. 1.9 9L (4.0 pints) NV271 ................................................................................................................................. ....................................................................... 1.89 L (4.0 pints) NV273 .............................................. .......................................................................................................................................................... 1.89 L (4.0 pints) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 9530 Fluid - Transfer Case: Fluid Type Specifications All Except NV246 Recommended lubricant for the NV241 GEN II, NV271, NV243, NV 244 GEN II, and NV273 transfer cases is Mopar ATF +4 Automatic Transmission Fluid. NV246 Recommended lubricant for the NV246 transfer case is Mopar NVG 246 Automatic Transmission Fluid or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9533 Fluid - Transfer Case: Service and Repair NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9534 Fluid - Transfer Case: Service and Repair NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9535 Fluid - Transfer Case: Service and Repair NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9536 Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9537 NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9538 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 9539 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9544 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9545 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9546 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9550 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9551 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9552 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9553 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9554 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9555 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9556 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9559 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9560 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9561 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9562 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9563 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9564 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9565 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9570 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9571 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9572 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9573 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9574 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9575 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9576 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9577 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9578 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9581 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9582 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9583 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9584 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9585 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9586 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9587 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9588 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9589 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9592 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9593 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9594 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9595 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9596 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9597 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9598 Mode Sensor Channel States Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9599 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9600 Mode Sensor Channel States